Up close and personal with Ken Block's Focus RS RX

100 Pages·2016·30.78 MB·English

Leading-Edge Motorsport Technology Since 1990
1
January 2017 • Vol 27 No 1 • www.racecar-engineering.com • UK £5.95 • US $14.50
Gymkhana Ford
Up close and personal with
Ken Block’s Focus RS RX
Dimple aero study Mini at Bonneville F1 overtaking study
Wing trick that could reduce How a tiny team hit 166mph Simon McBeath assesses
drag and increase downforce with a 970cc original Cooper 2017 aero rules with CFD
New_06-acac.mbAC.indd 3 22/11/2016 14:34
0 1
9 7 7 0 9 6 1 1 0 9 1 0 4
Racecar Engineering Volume 27 Dimples aero study Ford Focus RS RX F1 overtaking study in CFD January 2017
NEW. . . XKS SILICONE OUTER COVER
The evolution in FLUID HORSEPOWER™ continues... Gloss black Silicone covering over XK Aramid
braid reinforcement. Excellent protection
for BOTH ProPLUS & ProPLUS Xtreme.
XRP ProPLUS PROPLUS RACE REUSABLE
HOSE ENDS ARE
™ AVAILABLE
Race Hose
NOW!
ANTI-STATIC PTFE IS
COMPATIBLE WITH ALL AUTOMOTIVE
FLUIDS AND FUELS
A highly compressed, non-porous
matrix resists fuel permeation
RACE CRIMP
and diffusion.
HOSE ENDS
PATENTED Hundreds of styles.
SMOOTH INTERNAL TUBE MANUFACTURING
Choice of full hex or
Superior flow rates, minimum PROCESS
lightweight turned down
pressure drop AND ease of Creates a full PTFE
swivel nuts.
clean-out, not possible in smooth-bore hose for
Black is standard,
convoluted hoses. optimal flow with
also available in
external convolutions for Blue or Super Nickel.
flexibility.
EXTERNAL
CONVOLUTIONS
Promote hoop strength for
vacuum resistance and A CHOICE OF OUTER BRAIDS
supports tight bend flexibility. XS: Stainless Steel,
XM: Lightweight XtraTemp Monofilament
XK: Aramid Fiber, XT: Tube only for inside fuel cells
and New XKS: Silicone over Aramid.
ProPLUS
Xtreme
SUPERIOR
VACUUM SUPPORT ™
Race Hose
An engineered design
with an externally wound
Highly Kink-Resistant,
stainless steel wire that
provides great vacuum support A CHOICE OF Quite Possibly The Perfect
and tight bend capability. LIGHTWEIGHT BRAIDS:
Dry Sump Vacuum Race Hose
XM - XtraTemp Monofilament, XK - Aramid and
Go to NEW XKS: Gloss black Silicone over Aramid braid.
www.xrp.com to
learn more Follow us on Like us on
about the ProPLUS An exceptional achievement in Instagram @XRPracing Facebook /XRPinc
Race Hose™
product line. race hose technology...
UNITED STATES XRP, Inc.
5630 Imperial Hwy., South Gate, CA 90280
CONTENTS – JANUARY 2017 – Volume 27 Number 1
COVER STORY TECHNICAL
8 Ford Focus RS RX 41 The Consultant
Millions only know it from Gymkhana Nine, but at Brake proportion valves in racecars
heart Ken Block’s mount is a full-on 600bhp racer
45 Aerobytes
Part two of our Swift FF1600 aero study
COLUMNS
48 F1 aerodynamics 2017
5 Ricardo Divila We use CFD to examine new regulations
Is motorsport on the cusp of a revolution? 58 Dimple aerodynamics
7 Mike Blanchet Can dimpled surfaces aid aero performance?
With Audi’s exit, what now for the WEC? 66 Formula 1 chassis testing
The evolution of impact testing in GP racing
FEATURES
78 Danny Nowlan
16 Dome MC86B Super GT Sorting a Time Attack car at the track
The ‘Mother’ of all GT300s hits the track in Japan
22 Holden Sandman BUSINESS NEWS & PEOPLE
Australian Supercars-based ultimate track ride car
82 Industry News
27 Formula E insight Possible problems for Liberty; VAG bombshells
All the buzz as season three gets underway
86 Racecar People
30 Formula E roadmap A chat with Prema Powerteam boss Rene Rosin
FE’s plans for its future technology
91 Williams at Autosport International
32 Mini Cooper at Bonneville How ASI will celebrate UK team’s 40 years in F1
The 970cc original Mini that hit 166mph on the salt
98 Bump Stop
As always Macau provided drama
in spades this year, and not a little
controversy. Turn to Bump Stop at the
back of the mag for the inside story
Subscribe to Racecar Engineering – fi nd the best off ers online
www.racecar-engineering.com
Contact us with your comments and views on Facebook.com/RacecarEngineering
JANUARY 2017 www.racecar-engineering.com 3
Contents_MBAC.indd 3 22/11/2016 11:40
ACCELERATE INNOVATION
www.avl.com/racing
SIMULATE ENGINEER MAKE TEST RACE
avl_raAcVinLg L_ImSTa kFeP_ R21C0 JxU28L21.6in.inddd 1 1 12/05/21061.60 3 .1106: 0 213:14
STRAIGHT TALK – RICARDO DIVILA
Come the revolution
In a time of massive political upheaval could motorsport be next in line for change?
he Norse Eddas speak of Urth, Veroandi and new bureaucracy,’ said Franz Kafka, and Ludwig power, gave rise to an acceptance of institutions
Skuld, the Norns, maiden giantesses who von Mises went further: ‘Economically considered, inspired by the French Revolution, notably, universal
Tsee the past, the present and the future. war and revolution are always bad business.’ The systems of primary education which were put in
‘Thence come the maidens mighty in wisdom. Three arch-revolutionary Lenin was blunt in 1918: ‘It place everywhere. The Russian Revolution of 1917
from the dwelling down ‘neath the tree; Urth is impossible to predict the time and progress was a world revolution ultimately responsible for
is one named, Veroandi the next. On the wood of revolution. It is governed by its own more or the New Deal and European welfare states, as much
they scored, and Skuld the third. Laws they made less mysterious laws. But when it comes it moves as for Soviet Union communism.
there, and life allotted to the sons of men, and irresistibly.’ And more bluntly yet: ‘You cannot make My own generation’s revolution in 1968, much
set their fates.’ Quite. Presumably, if we ask them a revolution in white gloves.’ as 1848, broke out almost everywhere, from China
what the near future brings, we would be warned Looking at the motorsport scene, there are to Mexico, seized power nowhere, but nonetheless
that a revolution is coming. But do we know what a plethora of warning signs. These are more they changed everything in the end.
a revolution is? It used to be seizure It was a revolution against
of power by popular forces aiming to No public, no sponsors. No sponsors state bureaucracies, and for the
transform the nature of the political, inseparability of personal and
social, and economic system, according equates to the death of the business political liberation, whose most
to some dream of a just society. lasting legacy will likely be the birth
of modern feminism.
Norse power As I noted earlier, revolutions
Today, we live in an age when rebel are planetary phenomena. What
armies come sweeping into a city, or they really do is transform basic
mass uprisings overthrow a dictator, but assumptions about what politics
not necessarily with the consequences and society are ultimately about,
of a just society. On the other hand, the and the same applies to the world of
rise of feminism led to a profound social motorsport and its society.
transformation, which took an entirely As I also noted earlier, in the
diferent form and tends to infuence the wake of a revolution, ideas that had
basic fabric of society. As H Rap Brown been considered veritably lunatic
noted: ‘Revolution comes when human fringe quickly become the accepted
beings set out to correct decadent currency of debate.
institutions.’ One thinks the Norns
watching the world would say what we To the barricades!
have seen with Brexit and the American A generation later, even the stufest
election, and worldwide political unrest, magistrates, priests, and headmasters
are but the refection of a fundamental These days Russia has a grand prix (pictured), but 100 years ago it was on the had to at least pay lip service to the
malaise in all systems, which are the verge of revolution. But is motorsport now facing a revolution of its very own? ideas of the French Revolution. Before
result of old management and business long, we had reached the situation
models that are still governed by geriatric pertinent precisely because what is accepted as the we are in today: that it’s necessary to lay out the
and entrenched powers. modus operandi is directly related to the society terms for anyone to even notice they are there.
Revolutions are thus planetary phenomena. And it is embedded in. As global society increasingly They’ve become common sense.
there is more, for what they really do is transform becomes more integrated, these societies respond But the participants in motorsport are so busy
basic assumptions about what politics and society the same way. Immanuel Wallerstein noted that devising ways to go faster and beat the opposition
are ultimately about. In the wake of a revolution, by the time of the French Revolution there was a that they end up being like the general public in
ideas that had been fled as lunatic fringe quickly single world market, and increasingly a single world countries who are not involved in the governance,
become the accepted currency of debate. political system as well, dominated by the huge and are subject to private agendas of individuals.
Before the French Revolution in the 1790s, the colonial empires. Globalism is not new, just more And, in the case of motorsport, much like the
ideas that change is good, and that government visible. So the storming of the Bastille in Paris could world, the interests of global companies prevail
policy is the proper way to manage it, and that well end up having efects on Denmark, or even over the good of the sport, which depends
governments derive their authority from an entity Egypt, which were just as profound as on France ultimately on the paying public.
called ‘the people’, were considered the sorts of itself—in some cases, even more profound. The steady loss of audience refects the state of
things one might hear from the tinsel-hat crowd the business. No public, no sponsors. No sponsors
and demagogues, or in the best interpretation a Revolutionary zeal or investors, equates to the death of the business.
handful of freethinking intellectuals who spend The world revolution of 1789, the revolution of So, all you citizens of motorsport, hear my
their time debating in cafes. 1848, which saw revolutions break out almost cry: ‘To the barricades, and make motorsport
There is a caveat, as always: ‘Every revolution simultaneously in 50 countries, from Wallachia to great again!’ Oops, maybe this is not exactly the
evaporates and leaves behind only the slime of a Brazil, none of which were successful in seizing phrase one should use right now.
JANUARY 2017 www.racecar-engineering.com 5
Divila_Jan_2017_MBAC.indd 5 21/11/2016 11:04
XPB
C
M
Y
CM
MY
CY
CMY
K On-Track Accident Cover
Motorsport Commercial
Insurance for Event Organisers
Personal Accident
Road Insurance for Competition Cars
To find out more or get a quote then please
call 0115 965 1020 for Individual Policies,
0115 965 1050 for Commercial Policies
or email us at
SIDETRACK – MIKE BLANCHET
The departed
In the wake of Audi’s withdrawal from the WEC, what next for the top prototype class?
began writing this column celebrating what engines removed from the mix, plus Toyota having part-compression ignition, lean-burn technologies
is currently another golden age of Endurance converted from atmospheric to turbocharged and advanced anti-knock, all directly applicable to
Ir acing, with the close battles between Audi, engines and exchanging supercapacitors for the improvement of road vehicles, are where it’s
Porsche and Toyota works teams in the WEC, Ford batteries, therefore coming into line with Porsche, at. There is no doubt that the adoption of the fuel
v Ferrari again after half a century, plenty of drama, this variety of technologies has now reduced fow meter has focused the attention of the engine
fantastically, close fnishes, and heroic pitwork . signifcantly. As is usual in motor racing, over time designers into optimising the energy potential
Then I read the bombshell news of Audi pulling certain technical solutions come to the fore and of every fuel droplet, with dramatic results. This
out of the WEC. Perhaps not surprising really – become universally adopted, possibly negating the actually has been the real game-changer, frst
there must be a limit to the returns to be gained for likelihood of any other manufacturer entering the proposed by Keith Duckworth many years ago.
a high-volume car manufacturer after such a very WEC in order to show of its diferent approach.
long run of success. In Audi’s case, other factors The hard cell
contributed to the decision, not least a desire to ICE breaker The ACO says it wants to encourage fuel cell-
placate workers and shareholders following the Ironically perhaps, the drive to smaller internal- powered cars to enter and to lead more advances
massively expensive ‘dieselgate’ scandal in the combustion diesel and petrol engines enhanced by in technology, but it must be beware of following
USA for parent company VW, meaning something forced induction is starting to look less, not more, this philosophy too passionately. Being in line with
had to be seen to be done re cost-cutting. Audi’s relevant to passenger car development. A recent a changing world is necessary, but there is a fne
recent participation has all been centred on diesel Reuters news agency release stated: ‘Tougher line between this and retaining full capacity quality
power – perhaps something the VW board grids and exciting racing. I have every
didn’t think needed over-emphasising at respect for the success and nous of the ACO
present – and any automotive giant might in maintaining and enhancing the prestige
well query why a second race programme and value of Le Mans over so many years,
competing against another group company but perhaps another re-think is necessary.
– Porsche – can be justifed without As with F1, especially, chasing manufacturer
diferent technologies being employed. entries and green credentials might on the
face of it be laudable, but if this reduces the
Diesel genes competition because of excessive cost and
Although Toyota and Porsche still remain, the spectacle by too much technological
this means only four manufacturer cars excellence, what has been achieved? One
(an outside chance of six) taking part, not should always remember that the core
many when you consider the attrition rate activity is motor racing.
common in the Le Mans 24 Hours. However, Bruno Famin of Peugeot has stated
the deeper inference of Audi’s withdrawal With Audi’s announcement that it will no longer take part in the WEC that the WEC is not sustainable, even if the
is of course the potential knock-on efect the variety of competing technologies in LMP1 has been diminished spirit of the rules is good. He suggests a
concerning these two LMP1 marques. dramatic lowering of the minimum weight
The ACO has, from bitter past experience, been European car-emissions tests being introduced that currently stands at 875kg as one means to
aware of this threat. It has been trying to bolster in the wake of the Volkswagen Group scandal are achieve this. (Question: as long as the same safety
the non-hybrid LMP1 privateer ranks, but has so about to bring surprising consequences – bigger requirements are demanded and certain uber-
far ofered too little, too late, even with measures engines! Automakers are now being forced into a expensive materials and processes are banned,
including advantageous aerodynamics and costly U-turn as more realistic on-the-road testing should there be a minimum weight limit at all?)
freed-up engine regulations plus a slight weight- exposes deep faws in their smallest engines.’ Famin says: ‘There are three [now just two]
break being introduced for 2018. So it could be that the move to little internal major manufacturers who want to show of
That the ACO and the FIA together conceived combustion engines augmented by turbochargers their innovation and the technology they have
energy-based power unit regulations resulting is a bit of a blind alley after all. Coincidentally, and developed, but the costs are so high no one else
initially in very diferent concepts proving highly as in F1, it appears that the development of the will join them in those conditions. I would like to
competitive with one another was an amazing feat. complicated electric hybrid aspect has plateaued propose a diferent way of achieving efciency,
It’s claimed that these regulations encouraged Audi considerably, pending dramatic battery technology namely minimum weight reduction. If you want to
and Toyota to continue and Porsche to re-enter, breakthroughs for which the timeline is as yet reduce emissions and fuel consumption, there are
creating the great racing that I started out by unknown. Instead, the major gains in efciency ways of doing it without using hybrid systems.’
praising. But these LMP1 cars are wastefully heavy, overall are coming from developments in the Such observations, from a manufacturer with a
complicated, very expensive and supposedly not internal combustion engines which still form the great history at Le Mans, and a potential returnee
viable to supply to non-works teams. With diesel basis of the current power units. Pre-chamber and if conditions are right, should not be ignored.
Being in line with a changing world is necessary, but there is a fne line
between this and retaining full capacity quality grids and exciting racing
JANUARY 2017 www.racecar-engineering.com 7
Blanchet_Jan_MBAC.indd 7 21/11/2016 11:39
XPB
RALLYCROSS – FORD FOCUS RS RX
Blockbuster
It may act the flm star on Gymkhana Nine, but at heart
Hoonigan Racing Division’s Ford Focus RS RX is a 100 per
cent full-on rallycross machine, as Racecar discovered
By LEIGH O’GORMAN
Despite the short sharp shock
nature of Gymkhana videos, and
rallycross racing, aerodynamics
still play a decisive role
8 www.racecar-engineering.com JANUARY 2017
Ken Block_MBAC.indd 8 21/11/2016 11:42
or Derek Dauncey, team director always at heart a rallycross car, and there M-Sport [based in Cumbria in the UK and
of Ken Block’s Hoonigan Racing was rather more to this project than simply known for its Ford WRC programme] and they
Division, getting the Ford Focus RS putting a new livery on a Focus, as Dauncey built the current car,’ Dauncey says, adding
FRX prepared for flming Gymkhana explains: ‘We had been running a Fiesta for that the chassis confguration of the RS RX
Nine, the latest in Block’s hugely popular stunt a few years and we had been courting Ford is completely new, allowing Hoonigan
driving internet flms – which at the time of about going into the [2016 Rallycross] World Racing to develop a car almost specifcally
Blockbuster writing has accumulated 14.5 million views – Championship. They saw the opportunity of for rallycross competition.
was a fairly straightforward job. assisting us with designing a brand new car.’ Dauncey also explains that the gearbox
Following Block’s participation in the FIA tunnel on the rallycross car is much bigger
World Rallycross Championship in Canada, Race bred than the RS rally car, as both the exhaust and
the team made straight for the outskirts of The platform for the RS RX was the Focus RS propshaft run through that area.
New York, where the video was to be flmed rally car. However, when Hoonigan Racing The Ford RS RX rallycross car also runs with
and immediately began preparation. ‘We left completed an evaluation of the RS with double wishbone rods. ‘For the size of the car,
Canada and went straight down to Bufalo, M-Sport, it became clear that was precious we believed the double wishbone would have
did the livery change, did some repairs and we little that could be carried over. But this did an advantage, so that was the way it went
changed the settings and that was it; we went nothing to deter Dauncey and his team. forward. There’s hardly anything that carries
and did the flming,’ Dauncey says. ‘We wanted to try to take some forward [from the Fiesta] – maybe brake pads
But while the RS RX may garner attention engineering advantage. We were in and the turbo. That’s about it really. The whole
due to the Gymkhana flms, the project was discussions with Ford and Ford worked with design and theory was to basically not carry
JANUARY 2017 www.racecar-engineering.com 9
Ken Block_MBAC.indd 9 21/11/2016 11:41
RALLYCROSS – FORD FOCUS RS RX
While this Focus RS RX is known to millions for its
exploits in Gymkhana Nine it was built with its day job in
mind – racing in the World Rallycross Championship
anything over from the other car, but to revisit never make a transverse car work, but we could before in terms of gear ratios, gear widths,
everything once the installation started.’ see the benefts of it and we liked the idea of and we carried all that forward. We control it
Powering the RS RX is a 2.0-litre Ford making it with the Sadev gearbox.’ with a centre diferential release hand-brake
engine, which was developed by M-Sport and Feeling that it was a package that worked unit and a Sadev rear diferential.’
Ford Performance. Dauncey notes that the well in the Fiesta, Dauncey’s team worked hard Run via a slightly modifed clutch system
powerplant does have some carry-over from to fnely tune the centre of gravity and he feels from AP Racing, the package has proved
the engine’s original concept, and with over that the success of the RS RX has changed extremely strong, especially when considering
600bhp and more than 650lb/ft of torque, the some preconceptions regarding the weight the abuse it takes when getting of the line.
unit has certainly delivered. distribution of transversely mounted cars. ‘We
The engine has been mounted transversely looked at every option to help us of the line Cross-code
in order to help with weight distribution and and where we want that weight of the line, so Of course, it is one thing to be quick, but for
centre of gravity. ‘When they did that in the it’s a slightly diferent way of thinking, but that Block’s Gymkhana flms the car also needs to be
installation, they changed quite a few items on was the direction we took. spectacular. But Dauncey says that there was
the car to assist the angle of the transmission ‘There’s been some pretty good tricks done no trickery as such involved in making the car
and steering,’ says Dauncey. ‘We kept that in with the engine, but fundamentally it’s just a look good on flm – just solid engineering and
the whole philosophy. Some said we would 2.0-litre engine that’s very similar to what we good driving. But there are some changes when
used before, but much more advanced.’ it comes to the Gymkhana spec. ‘We’ve had a
The RS RX utilises a 6-speed sequential specifc turbo made that spools up quickly and
It is one thing to be quick, gearbox by Sadev, as well as a Sadev rear gives you a quick throttle response, so if you are
diferential and centre diferential release unit. sliding, you can accelerate out of it. We’ve done
but for Block’s Gymkhana Already having an existing relationship with a fair bit with suspension, as in really not making
Sadev from the Fiesta, Dauncey decided to stick the dampers work as efciently as they can, so
flms the car needs to with the French company. ‘We have a very good that they allow the car to slide more, so that was
working relationship with them,’ he says. ‘The basically carried over from the Fiesta. To be fair,
be spectacular, too gearbox is slightly refned from what we had the platform itself with the double wishbone
10 www.racecar-engineering.com JANUARY 2017
Ken Block_MBAC.indd 10 21/11/2016 11:42