And back to square one as the Stohr burns

May 11th, 2007

Well back to the beginning…well actually further back than the beginning if you consider in the beginning I actually had a full car. During my first outing this year the car had a major issue with an oil cooler fitting and burst into flames. Here is my account of what happened as I posted on Trackpedia.com in this thread: http://www.trackpedia.com/forums/showthread.php?t=2494

Stohr DSR sitting in the paddock getting ready

Stohr DSR sitting in the paddock getting ready

On the front straight moments before disaster

On the front straight moments before disaster

The smoldering hulk after she went up in flames

The smoldering hulk after she went up in flames

The burned Stohr from the side

The burned Stohr from the side

The sebtrab oil cooler that failed due to faulty brazing of fittings

The sebtrab oil cooler that failed due to faulty brazing of fittings

Not to much to say really other than at least I went out in impressive fashion. Had the first test day with the Stohr all back together at BIR yesterday and things were going great in the afternoon after some purely crappy weather and rain in the morning. Got in two great session in the afternoon and then came in to fuel up and head out for the last one. Little did I know it was the last one for a long time.

Had little teething issues all day but worked through them and figured the car wasn’t that bad and I had been lucky. My luck ran out on my 8th lap of my final session. Just turn in my personal best lap at 1:43 on the dash and headed down the front straight after passing Steve B in a SRF between 9-10 up to 140 under CarreraRS, PawPaw, Rob and others in the control stand with Conan up ahead and then turned in for one. Car squirmed and I looked in the left rear view and just saw a big orange glow. Thought first I just blew the motor, but then realized that it was on the opposite side of the exhaust so I checked my other mirror and same thing big orange ball. So pretty impressive site to see I can image…140mph (with given I could see nothing else in the rear view besides fire) with probably a 30 foot set of flames behind me in the middle of T1 at BIR.

First thoughts were honestly “why me?” followed by kill all the fuel, etc and get the car slowed down which was a pain as the fire was hot enough it was eating through the rear brake lines. As soon as I got the car straight and down to probably a 80-90mph I pulled the extinguisher and NOTHING happened. I dicked with the handle trying to pull it on the canister itself and nothing, pulled the dash handle one more time and said f*ck it I am out of here as I had fire now around me coming out the air intakes by my head. Slowly got the car down to 20 and just had my belts undone before she stopped rolling. Hoped out, ran away from the car and then just sat back and watched it burn.

What seemed like 30 minutes later but really was only a few the crew arrived on the scene and ran over to the car thinking I was still in it. Gary Curtis was the second one out there and also thought I was still in the car. After seeing I wasn’t we started spraying the car down. Fire crew had a hell of a time putting out the car as it was pretty much engulfed in flames from the cockpit back and as I am sure you will see in some pictures later was burning really damn hot and kept reigniting.

I’ll never forget looking up and seeing Sean’s face after Rob, Mike and him got out to the scene. I think the look pretty much summed up everything I was feeling. It was just one of amazement.

After getting the car scraped off the track and dumped off back in the paddock the Trackpedia crew…

(Sorry Gary Curtis just called to check up on me - Once again probably one of the nicest guys in racing. Pointed out a good visual parallel to my car from his vantage point of a WWII fighter being shot down with flames out the back is what my car looked like.)

…and I stood over the mass of mangled fiberglass and carbon fiber looking for the cause and there it was right in front of me. The top outlet of the oil cooler had blown right off the units body. Were not talking the AN fitting came off, no this is the whole threaded in section of the cooler blew apart. Thus 188 degree oil at 60 some PSI (I had checked passing the start finish line) came rocketing out all over the cowling and side pods when then ignited when it touched headers. The Trackpedia crew on hand helped my scoop the remains back into the trailer and haul it home. It now sits at another friends place a big piece of ash from cockpit on back.

This was going to be a really short update as I have of course been swamped at work but it turned out to be my full account. My feelings on all of this at the moment are mixed. Number one all I can think of is I am ok. When you look at where my belts were burned too as I was getting out of the car and when I think back to being able to see flames around my head while still moving at a good clip I am happy I don’t have a scratch on me. Also considering this was at the turn in to the fastest turn in North America at 140+ mph I got damn lucky I didn’t end up upside down or worse. Secondly I just am thankful that I have the friends/TP buddies I do that were concerned enough about me to have the expression Sean had and the concern Rob, Steve, Conan, Dave Billy, Eric, and Mike had. Lastly I am pissed that I didn’t do this to my car. I can handle my mistakes breaking something or me screwing up but I just turned in my best lap ever in the car everything was perfectly fine with the gauges and then as David Hobbs would say Kablamo. A stupid part rated to a way higher psi then I was running blew up. I really wish I had screwed up because then it would have been on me and I feel much better when its my fault.

If I had a car I would be back in it tomorrow. As long as it was painted Black and silver with the number 4 on it carrying the Trackpedia logo proudly. So rust in peace Stohr S/N 13. You were the most awesome thing I have ever been in…to bad our time together didn’t even include the first race that I had bought you for.

So the process starts. Back to the garage tomorrow to sawzal off the burnt up body and attempt to take apart engine and out of the chassis. Fricking sucks but with the help of my friends and of course my wonderful wife understanding my obsession maybe the car will be back together next Spring. Who knows but luck was on my side and I got out of the car so like Bill Murrary says..”So I got that going for me.”

Cars, DSR, Stohr , , ,

One step closer

April 15th, 2007

Spent all yesterday pretty much in the garage with Eric helping me in the morning with getting the cooling system to run and then dorking around by myself at night trying to get the oil system in working order.

The water system was a bear. Lets just say that I had more fricking air bubbles in the system than I could have ever imagined and they were harder than I ever could have imagined to get out. We started working on the cooling system about 8 and by 11 had things running and the little Davies Craig electric water pump spinning away. The main bear was just getting the coolant to pump up into the motor. The bikes have a intake to the water jackets at almost the bottom of the engine under the headers. Getting water to flow uphill as we all know is a royal pain in the ass! Then the radiator had a really goofy issue with the main inlets being about 3/4 the way up the radiator so as you can imagine this creates a lot of issues with getting all the air out of the system. I had to pull a plug on the top of the radiator to get her to push all the air out but it wasn’t easy. ;) I still honestly am not comfortable that the setup is correct as it just does not seem that I am able to flow enough water through the system but then again the switch to Evan’s coolant and a little bit of advice from a Yamaha tech have me thinking it might not be too bad. Right now my plan is just heat cycle and try to bleed again later.

Hopefully today I can get her to fire for the first time. :)

Cars, DSR, Maintenance and Assembly, Stohr , ,

Chassis is complete, Wiring underway.

April 10th, 2007

The 05 Yamaha R1 tucked away in the custom engine mount

The 05 Yamaha R1 tucked away in the custom engine mount


Rear view of the 05 Yamaha installed

Rear view of the 05 Yamaha installed


Rear view of the 05 Yamaha installed

Rear view of the 05 Yamaha installed


The shifter install pull/push cables

The shifter install pull/push cables


Well the eagle has landed! My baby is finally back in my garage and looking, well, remarkably like a car again considering how completely stripped down she was when it rolled out of the garage and up to Carriage House Customs. It took a hell of a lot of work and without the excellent craftsmanship from the folks at Carriage House it would never EVER have been possible. Overall the cost was something I could stomach and much better than a few other conversion kits (Infact carriage house still has all the jigs if others want the same conversion completed) that I had looked at.

The real cost that came into this whole upgrade was the dry sump conversion as that is where the majority of cash was spent with the cooler, hose, dry sump itself and other related expenses. Behind that was the cost of the rework of the engine cradle. I hope to have a full break down of costs and work that was done here in the near future when I get a shot after the car is running here and gets it annual tech finished on April 21st. I would love to have this become a guide to other looking to do the conversion as while it was tough I think the upgrade to the newer engine will be well worth while.

Tonight with the help of my buddies Rob and Eric we got the wiring harness, fuel cell and battery back in the car and working. All in all about 4 hours of time which isn’t bad at all considering the knowledge base of doing this on a DSR was zero. :) Main trick was just getting the wiring correct as there were some interesting bits dealing with the change from the 99-03 engines using a power interrupt based starter switch to the 04-06 motors using a grounded starter switch. Once we worked through that it was testing circuits and THANK GOD the fuel pump spun up AND the starter kicked on for a brief second (”hey rob try it now! BuZZZZZZ”). Thursday night hopefully will be dedicated to finishing up the wiring harness and plumbing in the fuel system as well as the new remote water pump.

I will snap pictures of the work as it progresses but here are some as she came straight back from the shop on Friday.

Cars, DSR, Maintenance and Assembly, Stohr , , ,

My racing schedule

April 7th, 2007

Well just typed up a nice big long entry and what happened…of course it disappeared when I tried to post it. Mother F*cking software. :)

Anyway now a much shorter entry on my race schedule this year

May 19/20 - Mid America Motorplex - Midwest Division Regional/National

July 7/8 - Blackhawk Farms - Central Division Double Regional

Aug 24/25 - Road America - Central Division Double Regional

Sept 8/9 - Brainerd International Raceway - Central Division Double Regional

Sept 29/30 - Milwaukee Mile - Central Division Double Regional

I am going to do a Skippy lead/follow as well during June I believe so hopefully that will get me a little more comfortable at Road America as I really would love to get more seat time there and what better way than with a instructor following your ass.

Update on the car is that its at home and will hopefully be running by this coming weekend. I have fuel lines and wiring yet to do but I can’t see it taking much more than a few nights to get that done. Then its time to hit the starter button and crank it over for the first time…man oh man if she starts the first time I will crap myself!

Racing, Racing School, SCCA Club Racing , , , , ,

Stohr final mockups and chassis photos

March 21st, 2007

Spring is in the air and my mind keeps wandering to racing. <img src="http://www.trackpedia.net/blogs/john/templates/default/img/emoticons/smile.png" alt=":-)" style="display: inline; vertical-align: bottom;" class="emoticon" /> Good news is my car is coming back together quickly in the chassis department. Attached below shows the car in almost its final state at Carriage House Customs after some great work by Steve. The new engine was a hell of a lot more work than first thought as the new engine leans a lot more forward than the old one which required header mods as well as just the chassis work. In the end however it will be worth it if this thing is as bullet proof and reliable as I expect a EFI engine to be versus the old carbed on. <br />

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Another modification I had to make here lately was going with a custom oil tank versus the one I had purchased from Pegasus which was just too tall for the engine compartment. Its amazing how tightly packed the engine compartment is when you start to attempt to fab in what you need to support the engine. <br />
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Lastly I got my wiring harness tonight via UPS from George Dean and can't wait to hook it up to the bike and press the button and….of course have nothing happen. Its only my luck. <img src="http://www.trackpedia.net/blogs/john/templates/default/img/emoticons/smile.png" alt=":-)" style="display: inline; vertical-align: bottom;" class="emoticon" /> I know George did a great job but as usual something has to go wrong. <br />

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The Stohr’s new engine mounts

March 13th, 2007

So after weeks of waiting for choromoly in the correct thickness to come in without having to buy it in quantities the size needed to build aircraft the car is coming together. Just need to box the rear of the mount in so that the rear trailing arms going to the spar can connect. Then wash rinse repeat for the other side. <br />
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Plan at the moment is to get the girl back by the end of March, spend the first two weeks of April burning the midnight oil to put the car back together and then fire it up by mid April. That means I should be able to shake it down in a local parking lot and be ready for the first on-track shake down on May 7th with Donnybrooke at <a href="http://www.trackpedia.com/wiki/Brainerd_International_Raceway" title="BIR">BIR</a>. <br />

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Let's just say i cannot wait to get this car and myself back on the track. I can't stand driving around the 4Runner during the winter months…longing to hear 14000 RPMS and the wind buffeting my helmet at 140. <br />
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So your probably sick of my helmet by now huh…

March 1st, 2007

So Mike sent me an absolutely great show of my almost completed helmet. Tell me this baby doesn't look awesome! With regards to my car I am sorry i have been so lax in update, well I haven't been lax its just been that absolutely nothing has happened. I am starting to think that the Stohr is resembling my Ferrari in the way that both just seem to make money disappear out of my bank account every winter. Of course for the cost of a fricking Ferrari wheel bearing I am having half the chassis rebuilt…so I got that going for me.<br />
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I keep going up to Carriage House Customs to drop off parts and keep forgetting my damn camera along so I never have anything to really update you with here. Basically lots has happened. Last week I put the new fuel pump in the fuel cell which was a nightmare. Had to rewire the connector and then try to push the pump into the fuel safe cell's pump holder which if I would equate to being about as difficult as giving birth in that it was pushing an object to big through way to small of a hole. <img src="http://www.trackpedia.net/blogs/john/templates/default/img/emoticons/smile.png" alt=":-)" style="display: inline; vertical-align: bottom;" class="emoticon" /> Aside from that George Dean is about done building my new wiring harness so that should be here next week. Beyond that I just sit around making car sounds imagining I have the DSR back while playing the new F1 game on PS3. <br />

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Yep I am sick like that. But hey what else can you do when you have had about 30 inches of snow in the past 4 days. <img src="http://www.trackpedia.net/blogs/john/templates/default/img/emoticons/sad.png" alt=":-(" style="display: inline; vertical-align: bottom;" class="emoticon" /><br />

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Hopefully I will be back soon with a lot more pics of the chassis rebuild.<br />
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Helmet moves along while the car stalls

February 18th, 2007

So my helmet is looking just plain SWEET! Mike has been busy laying down paint on here and she is looking beautiful. Check out the pics below of the excellent work! My car on the other hand is at a stand still. We are waiting on the machine shop to finish up the bushings for the motor mounts and then should be able to start getting the car ready for the summer. I got all my parts over the last week here. Barnett kevlar clutch, DID chain, Ivan's smog block offs, Setrab oil cooler, etc are all sitting at my house ready to drop into my baby when she rolls home. I promise more pics of a naked Stohr (No not Lee) this week so you loyal readers can see whats going on.<br />
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Anyone have any opinion on Pigel shifters? Thinking about sticking one on but would like an opinion on them before I do. Specifically downshifts and leftfoot braking cooperation.<br />
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New helmet is starting to shape up

February 9th, 2007

So my new lid got off to Mike Charness to have painted after Mike Skeen won the Trackpedia helmet painting contest. The design is migrated slightly to personalize it a little more for myself but I am about as excited as a kid on Christmas after seeing Mikes original designs and initial work. I think the color scheme is perfect for the Stohr with the red parts of the helmet being Ferrari red (Rossa Corsa) in memory of my old girl. Check out the initial pics and 'almost' final design!<br />
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Installation of a Taggart Dry Sump

January 29th, 2007

Well since the car is still waiting to get the new engine cradle welded on due to the fact the that the shop needed to order some special order chromoly pieces I decided to bring the engine back home and install the dry sump kit while I had a chance so that once the engine was in the car it was in the car for good. Let me just say that if you need a dry sump kit for your R1 nothing beats the quality of the Taggart system (<a href="http://www.tpe-inc.com/" >http://www.tpe-inc.com/</a>).<br />
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Rob came over about 7:30, we had to run to Walmart for some RTV and Blue locktite so we got started about 8pm at getting this baby installed. I had already removed the old water/oil pump a few weeks back and it probably toook about an hour max. Installation was even easier! We started by breaking out the excellent directions Taggart provided and getting the required tools out. After that first step was checking the old o-rings to ensure they were in good shape, then dropping in the new pump. We followed that by getting the oil feeder and return ports installed into the block. After that it was a quick tightening of the two main mounting bolts, the three oil pump bolts and she was secured. We followed that by probably the most difficult part of the task which was getting the oil pump gear installed back into the drive chain. Once we get that installed we tightened the drive chain's bolt, installed the oil/water intercooler block off and it was all done! Now I just have to wait for a new oil pan gasket coming from the local bike shop for a whopping $6.14 and then install the new pan and everything is ready to roll. <br />
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I really just want to say again how damn impressed I was with the quality of the Taggart dry sump kit as well as just Yamaha's engine in general. I have never worked on such a sweet well put together engine.<br />
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The pictures below are of the dry sump, looking at the dry sump from the bottom of the engine, and the pan and oil/water block off.<br />
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