The historic former team Nasamax car, renowned as the first alternatively fuelled competitor at Le Mans, is set to make a welcomed return to endurance racing after race entry criteria was reviewed, allowing a broader range of cars to compete. In the process a change from 5.0 litre to 5.5 litre Judd V10 engine was decided upon, necessitating a redesign of front and rear Engine Mountings and associated components. Engineers from KW Heritage (KWH), a division of KW Special Projects (KWSP), jumped at the chance to design, manufacture, supply and install the solution – a one stop shop.
- Assess the differences between engines and compile a costed job list for discussion with the customer.
- Stay within tight budget and time constraints, using digital manufacturing to advantage on this one off project.
- Augment the initial CAD assembly of 3D models by the use of 3D scanning to provide a robust digital assembly around which to design a solution.
- Design and manufacture a replacement carbon-fibre Front Engine Mounting Beam using 3D printed mould and loose tools. Designed to be self-positioning when bonded to the Chassis – no requirement for costly final machining or bespoke one use Jigs.
- Design a replacement Rear Engine Mounting Shear Plate, building in the capability for rapid Alternator Belt changes.
- Design and manufacture a simple carbon-fibre Airbox Adaptor Ring that overcame differences between old and new Airbox Trays – the original Airbox, with its restrictors and filter, were retained.
- Advise on the manufacture and procurement of replacement Exhaust Primary pipes and other components.
- Redesign and manufacture a Starter Ring Gear to suit a new type Clutch assembly.
- Provide staff and materials to execute the removal of redundant carbon-fibre engine mounting structures and the installation of a replacement and all other new components.
- The broad range of skills and capabilities shared between KWH and KWSP, centred around its engineering core, allowed the team to take the initial remit from the customer and deliver an exceptional solution.
- The process of managing the project from inception to conclusion included regular consultation with the customer and guidance for them when procuring related components and assemblies.
- When coupled with the use of scanned data and the considered deployment of digital manufacturing techniques, the results lead to efficiencies that are tailored towards, and directly benefit, specialist projects.
- The full range of in-house skills were deployed and project managed to achieve a positive outcome: Solidworks CAD design, 3D scanning, additive manufacturing, procurement, supplier liaison, inspection and off-site, technician led installation.
“We are very pleased with the design and fitting work KWSP did for our engine installation. Very helpful and always clear in communication throughout each process of completing the task. Thank you.”
Robbie & Dean Stirling, Team Nasamax
For more information on KW’s range of Heritage Engineering services, visit the KWHE website.