Tuned In

Over the last few years, we’ve seen a massive increase in the availability of ultra-high-performance billet parts — especially blocks and heads. This week’s guest, Chris Smith of Crest CNC, was one of the pioneers of this practice in the import category, but now he’s branching out from the 5-axis CNC and heading to the foundry to produce cast engine parts — we find out why.

Use “CREST50” to get 50% OFF our HPA 3D Modelling & CAD for Motorsport course: https://hpcdmy.co/CADb

Chris Smith came up in the trade as an engine reconditioner, before buying his first CNC mill and starting on a career path that would eventually see his business become the go-to supplier of billet blocks and heads for some of the world’s fastest racers, as well as the odd OEM manufacturer.

This week’s conversation first jumps into the ins and outs of metallurgy and tribology (which, by the way, is the study of interacting surfaces in motion). We learn the difference between various materials commonly used in high-end performance applications — like 6061 and 7075 aluminium, for example —  as well as the pros and cons of different 3D scanning tools, coordinate measuring machines, and CAD software.

The conversation then steers itself towards the weaknesses of both Nissan’s VR38 and Subaru’s EJ motors, delving into how failures occur and how Chris addressed them with his billet block and head offerings. While on the subject, Chris also goes into detail on the advantages and disadvantages of wet and dry cylinder sleeves, as well as the reliability and maintenance requirements of billet engines.

This naturally brings us to the elephant in the room — why a billet engine specialist is now offering aftermarket cast engine products. Chris lays down the reasons why it’s a good idea, and takes pains to explain how aftermarket cast is very different from the cast blocks and heads that come off an OEM manufacturer’s production line.

Are aftermarket cast engine parts the way of the future? Listen to this episode with Chris Smith of Crest CNC and come to your own conclusion.

As discussed, you can listen to Tony Palo’s episode here: https://hpcdmy.co/tonypalo

Follow Crest CNC here:
IG: @crest_cnc_pty.ltd
FB: CREST CNC PTY. LTD.
TIKTOK: @Crest_CNC
WWW: crestcnc.com

Don’t forget, you can use “CREST50” to get 50% OFF our HPA 3D Modelling & CAD for Motorsport course: https://hpcdmy.co/CADb

The iC-7 is getting a birthday, and it’s backwards compatible.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

The iC-7 has always been a display-only device and has been priced accordingly, but with an upcoming firmware update, some added functionality is coming, all without any hardware changes, payments or strings. Further to this, the dash will now be controlled within Haltechs NSP software rather than the old standalone ICC software.

Scott Hilzinger also has some other major news, @haltech is also ready to open up their CAN protocols to the public, making it easier to integrate their products with a wide range of others for those who have the desire and knowledge to do so. This has come due to popular request, and the fact that all levels of the performance industry are simply better equipped to deal with CAN communications these days compared to just a few years ago.

This was filmed at the 2023 @WorldTimeAttackChallenge in Sydney, Australia.

If you want to learn more about CAN communication, yes, we do have a course on it and yes, that coupon above will get you a discount 💰🧠

You can design whatever you like using CAD for 2D and 3D modelling, but how do you get it off the screen and onto your project?

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

Founder and CEO, Jim Belousic of @sendcutsend, runs us through what a rapid manufacturing company like his is, what it can offer and what some of the most common pitfalls are for those just learning how to turn images into objects.

Accepted file types include .dxf, .step, .stp, .eps, and .ai, with STEP file types being a more recent inclusion and an option that can require some extra customer guidance when it comes to bending & bend reliefs, geometry sizing, and placements are going to physically work for the manufacturing process. Advice is also given on material choices for manufacturing, noting a rapid manufacturing company like SendCutSend will not engineer a part for you; they are just there to help you make it.

Design for manufacturing (DFM) and design for assembly (DFA) are also discussed with the likes of tab and slot aka self-fixturing design features helping to massive cut down in physical manufacturing time for those that employ them when compared to getting set up with magnets and clamps before welding. An example of this was at their 2022 SEMA stand, where 190 hours of design work took only 22 hours to make.

Some manufacturing options companies like SendCutSend offer will include: Laser cutting, CNC machining, waterjet cutting, bending, anodizing, countersinking, plating, and tapping.

**We're spending a couple of weeks away from the microphone over the Christmas and New Year period. This means that although we won’t be publishing any new guest appearances until mid-January, we’re going to be bringing back some of our favourite older episodes that deserve another listen.**

You might not know the name, but you’ve probably seen Sam Albert’s Subaru WRX online. Powered by a screaming 4.3-litre Ferrari V8, Sam’s flame-spitting AWD rally car is fast, it’s cool, and it sounds amazing … But why go to all that trouble when Subaru’s own EJ drivetrain — the one that this car uses from the factory — has proven itself a capable championship-winning setup since the late eighties?

Use “SAMALBERT50” to get 50% OFF our HPA Race Driving Fundamentals course: hpcdmy.co/driverb

This episode of Tuned In kicks off with a look into Sam’s history with cars and rallying — something he first competed in back in 2010. He’s also spent time as a driving instructor for DirtFish, so we couldn’t pass up the opportunity to discuss driving techniques like weight transfer, left-foot braking, handbrake turns, and much more. Sam also gives us some key tips on how someone new to the sport of rally is best to get into it and start building their first race car.

We then get to the meat and potatoes of the episode, as Sam gives us a full rundown of his incredible Ferrari-powered NA-AWD class build. This conversation covers all aspects — starting with why he decided to go down this route — with a car he bought off the lot brand new, no less — in the first place. Sam then discusses what led him to the Ferrari V8, how he worked around the rule book to build something unique, as well as the many challenges that came with fitting a motor like this into his Subaru shell.

It’s important to note that Sam doesn’t actually work in the automotive industry as a professional but instead learnt how to do things himself, including using HPA’s courses to learn how to wire his car. He’s also learning 3D modelling in order to design one-off parts for the Subaru — something that comes in handy for a one-off project like this.

With some informative conversations covering tuning around inlet restrictors, the pros and cons of other engines that were also considered, as well as a great explanation of what the car is like to drive and what gives it an edge, there’s a whole lot of interesting topics to dive into in this episode.

Don’t forget, Use “SAMALBERT50” to get 50% OFF our HPA Race Driving Fundamentals course: hpcdmy.co/driverb

Follow Sam here:
IG: @samalbertrally
FB: Sam Albert Rally
YT: Sam Albert Rally
WWW: samalbertrally.com  

Autodesk Fusion 360 is still a 'new player' comparatively in the CAD/CAM software world, yet it is already more popular than man options that have been around for decades.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

During SEMA, Josh Reader of Autodesk gave us a quick run-through on some of the features that have helped Fusion 360 become so popular so quickly and helped us understand what some of the terms and workflows for CAM (computer-aided manufacturing) and CAD (computer-aided design) projects.

Some great key points for you here include clearing up misunderstandings on generative design and manufacturing, why simulation is used before running a project on a machine and the advantage of having software that is almost 'all in one' when it comes to iterative changes between you and your chosen machinist.

What is Fusion 360? 

Briefly, Fusion 360 is a cloud-based 3D CAD/CAM solution for product (in our case, race car parts) development. It combines industrial and mechanical design, simulation, collaboration, and machining in a single package. It's an excellent option for makers who want to create their own designs or prototype parts with greater speed and efficiency. Although it may seem intimidating when people like Josh emphasize the importance of knowing what you're doing, remember that everyone starts from scratch. Even learning just one thing about CAD/CAM today is a valuable addition to your knowledge, which can be further expanded upon tomorrow. Over time, these incremental learnings accumulate to form a vast breadth of knowledge and experience. Remember, it all begins somewhere (and for 3D modelling that somewhere might be the HPA CAD course 😉).

Sick of cracked OEM cast blocks but don't have the use case for a billet alternative? Platinum Racing Products has something for you and your RB26-powered platform in the works.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

For years there has been a massive options gap between those who want to keep the likes a RB26 stock and those who race Pro Mod level drag cars producing 2000++ horsepower. Does an aftermarket ductile iron cast block bridge the gap for those in the middle who want to produce some serious power without the cost or complications of a billet block on a Nissan RB26-powered car that sees both street and track/race use?

Herman Urriola of @prp-platinumracingproducts7915 thinks so, and we'd agree.

In this interview, Herman and Andre run through some of the main flaws the Nissan and Nissan Heritage factory cast RB26 blocks have by discussing how PRP's ductile iron replacement via Crest CNC has addressed them. This includes superior material in the form of ductile iron giving greater rigidity, a 4 bolt main, 8mm bore thickness instead of the 3.5mm low that some Nissan RB26 blocks have, 14mm deck, improved serviceability and capacity options via sleeves, better oiling and head stud/main stud options to suit a range of built levels & demands.

Also touched on is why horsepower won't kill your OEM cast block, but rather cylinder pressure does (a topic we've discussed many times before) and why a billet aluminium alloy block simply doesn't suit 99% of those wanting to drive their car on the street.

We look forward to seeing this go into production, and Herman also gives some insight into what that process looks like in this day and age for aftermarket manufacturing companies like PRP. 

Executed well, this aftermarket RB26 casting can handle high cylinder pressure. However, for applications where it becomes too heavy, a billet block will be the alternative so it's certainly not the end of them. Like many parts, it's simply not a matter of 'this vs that,' but rather finding the right fit for the different use cases and accepting the tradeoffs.

PS: While we just focused on the block, PRP is also working on an RB26 cylinder head.

**We're spending a couple of weeks away from the microphone over the Christmas and New Year period. This means that although we won’t be publishing any new guest appearances until mid-January, we’re going to be bringing back some of our favourite older episodes that deserve another listen.**

The 2JZ-GTE isn’t Toyota’s only iconic tuner engine — before the famous straight six was anywhere near production-ready, enthusiasts and racers were already years deep into the development of the venerable 1600cc four-cylinder 4A-GE. In this episode, we sit down with Matt Trevena of MT Performance Engines to discuss everything Toyota 4A-GE, engine building, and much more.

Use “MTPERFORMANCE50” for 50% off our HPA Engine Building Fundamentals course here: https://hpcdmy.co/enginebuild

As a teenager, Matt Trevena fell in love with a neighbour’s 4A-GE powered KE70, and that exposure, combined with a healthy dose of Initial D, started Matt on a path that would shape his entire career, culminating in where it is today, building some of the most hardcore 4A-GEs around — including a genuine holy-grail Formula Atlantic motor.

Matt spent the first few years of his career building everything from lawnmower engines to massive car-sized 16-cylinder train engines before jumping on board with Sydney’s Maatouk’s Racing to put together big-power RBs and everything else in between. Now running his own performance engine building company, Matt has become the go-to guy when it comes to hardcore Japanese motors — but especially the Toyota 4A-GE.

As you probably already guessed, this episode goes way deep into the weeds on all things 4A-GE, covering the differences between the available variants, the best combinations of parts and generations, how to extract the most power, revs, and longevity out of them, as well as a deep dive into the ultimate 4A-GE — the Formula Atlantic motor.

This conversation also covers plenty of general performance engine building information, so even if this classic Toyota motor isn’t of particular interest to you, the knowledge found in this episode makes it a must-listen for any self-respecting enthusiast.

Follow MT Performance Engines here:
IG: @mtperformanceengines
FB: MT Performance Engines
YT: 199niko199

Don’t forget, use “MTPERFORMANCE50” for 50% off our HPA Engine Building Fundamentals course here: https://hpcdmy.co/enginebuild

You might argue that it's not hard to build a better Ferrari than Ferrari could in the 80's, but good fabrication is only half the battle when it comes time to hit the race track and dial it all in on the international stage.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

With very little stock Ferrari left, this 640hp at 14psi (1000hp capable future proofing included too 👌) could be expected to face some massive teething issues and hours upon hours of adjustments before a major motorsport event, but that is not how Mike Burroughs of StanceWorks rolls, nor does he need to after putting the hard yards into to logical and quality fabrication work over the last few years.

With a quick pad change to counter some brake bias issues, Mike was setting lap times out the gate, also thanks to time spent on the simulator pre event. This left the team free to make methodical, iterative changes over the weekend so Mike could chase his personal goal of continuous improvement remembering he is an expert fabricator, not Logan Sargent (which is a good thing in a way since it meant he didn't crash).

Mike and the crew did have some gearbox issues a while after this interview. It's all covered by some very polished content on the@stanceworks YT channel. It's well worth the watch.

What would be done differently if the clock could be reset and can we expect Mike back at the World Time Attack Challenge again?

The factory design of engine blocks did not anticipate the extreme boost pressures we see today, often struggling to even handle 15 psi let alone 100 psi or more which many are pushing down the drag strip. Fortunately, there are aftermarket modifications available that allow us to push the limits without the risk of splitting our engine blocks in half.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

Modern engine builds now achieve power levels that were unimaginable not long ago, especially in small 4-cylinder applications, with boost pressures exceeding 100 psi. Products like Darton Sleeves have turned this once-unbelievable potential into reality.

John Catapang from @DartonSleeves1 answers our questions regarding the limitations of OEM sleeves and how their MID sleeves and improved fitment have addressed these issues. He also discusses the importance of precision machining and selecting a knowledgeable company, as a bad one certainly won't foot the bill for replacing your entire engine if they overpromise and underdeliver. Make sure to do your due diligence and choose a reputable company capable of delivering repeatable results.

Six-second Supras, monster GT-Rs, dyno tuning discussions, and much more — this episode with Varun Sharma of 101 Motorsport has it all.

Use “101MOTORSPORT200” to get $200 OFF our HPA VIP package: https://hpcdmy.co/vipb

Varun Sharma and his business, 101 Motorsport, first came to our attention eight years ago when we first laid eyes on the impressive “Mighty Mouse” Honda CRX build at World Time Attack Challenge. Since those days, we’ve been keeping tabs on Varun and his various builds and now we’ve finally managed to pry him away from the workshop for a couple of hours to jump on the podcast.

Varun started young, gaining a fascination with anything mechanical through tagging along with his father to strip cars at scrap yards in search of replacement parts. Then, a few years later, when Nissan dropped its dominant R32 Skyline GT-R right on top of the Fords and Holdens at Bathurst, Varun was sold on all things JDM.

This pushed him towards the automotive trades, starting as an apprentice mechanic at 101 Motorsport and absorbing as much information as he possibly could. A few years later, Varun had the opportunity to buy the business and he’s been pushing the boundaries of what’s possible on the strip, the street, and the race circuit ever since.

101 Motorsport offers a huge range of services, so this conversation is a wide-ranging one that discusses topics like dyno tuning, engine building, methanol tuning considerations, drag racing strategies, tuning for driveability, the business side of the equation, and a whole lot more.

This episode is a great listen that has a little bit of something for everyone.

As discussed, you can watch our interview with Varun discussing the Oceania Supra here: https://youtu.be/WqVo2KsT7os?si=UpSHJzM6HWvwTgt6

Follow 101 Motorsport here:
IG: @101.motorsport
FB: 101 Motorsport
WWW: 101motorsport.com.au

Don’t forget, you can use “101MOTORSPORT200” to get $200 OFF our HPA VIP package: https://hpcdmy.co/vipb