Tuned In

Have you ever needed to get a part custom-made and been shocked at just how much it cost? In this episode of Tuned In, we sit down with Dan Melling from Kiwi CNC to find out exactly what’s involved in making bespoke one-off parts — from the initial measurements to the 3D modelling, to the prototyping, and to the milling and finishing of the final product. Once you’re done with this episode, you’re going to have a solid understanding of machining in the motorsport world, and maybe even pick up a few ways you can do some of the leg work yourself to save on the final bill.

Use “KIWICNC50” to get 50% OFF our 3D Modelling & CAD for Motorsport Course: https://hpcdmy.co/CADb

Growing up, all Dan wanted to be was an Air Force pilot, gaining his pilot's license while still in high school and then joining the New Zealand Air Force as soon as he could. While the pilot gig didn’t work out, Dan was still exposed to the world of machining, quickly building up his knowledge and skills while still in uniform. Once it was time to venture out into the civilian world, Dan worked in the aeronautical industry designing and machining parts from scratch before eventually deciding to commit to starting his own business catering to high-end automotive machine work. Thus, KiwiCNC was born.

Over the following years, Dan crafted a business that produces some of the prettiest billet components produced anywhere in the world, covering everything from sumps to suspension parts, diff covers, and plenty of one-off custom work.

In this episode, we get Dan to break down every aspect of his business and explain it thoroughly. This covers everything from the bare minimum amount of equipment to start a machine shop, the prototyping process, how CNC machines actually work and what’s needed to run them, plus much more.

We also cover 3D modelling and discuss whether generative design is actually useful in the real world and not just the latest buzzword. Dan then lays down a great impromptu 3D printer buyer’s guide and some excellent lessons he’s learnt running a small business that caters to customers who are willing to spend big money for the products he’s able to produce.

Even if you have no interest in getting into machining yourself, the knowledge found in this episode is going to be invaluable when the time comes to design your own parts and find someone to create them.

Watch the amphibious van news segment here: https://youtu.be/HDzTE_a0VYQ?si=Ge6hnJw1yhfW0ZDp

Follow KiwiCNC here:
IG: @kiwicnc
FB: Kiwi CNC Ltd
WWW: kiwicnc.com

Don’t forget, you can use “KIWICNC50” to get 50% OFF our 3D Modelling & CAD for Motorsport Course: https://hpcdmy.co/CADb

Data logging can seem daunting, but ultimately for limited costs and inputs, it can help make you much, much faster on track than many realise.

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It's generally assumed that you need to be a Race Engineer or have access to a team of them to make the most of data, but as Roger from AiM Sportline highlights, that just simply isn't the case. With a few main inputs, specifically speed, lateral and longitudinal g-forces, and your GPS position on track, it's possible to see where on track, or even map one out, you're fastest and slowest, as well as calculating your lap times.

What channels should be added from there is covered, along with the fact that many modern vehicles have these sensors as OEM standard, just waiting for you to tap into them.

With a unit like the AiM Sportline Solo2, a standalone data logging device, you can use this data to work out split times around the track, set reference laps and in realtime see where you are by comparison to that reference or your lap times throughout the day.

Roger also explains how the inaccuracies of GPS/GLONASS about positional data are not a major setback these days, both about the number of satellites in the sky and the accuracy of relative data.

The Toyota 86/Subaru BRZ platform is extremely popular in the enthusiast market for plenty of reasons. It’s simple, it’s rear-wheel-drive, it handles, it’s cheap — and there are few platforms out there that have the kind of aftermarket support that the ZN6 has. This is all to say that building one of these cars to a level where it stands above the rest takes something a little special. Cam Cocalis, this week’s guest, knows this all too well, having built one of the most impressive 86s out there, and one that was good enough to find its way into the top 12 of last year’s SEMA Battle of the Builders competition.

Use “CAM100” to get $100 OFF our HPA Motorsport Fabrication Package: https://hpcdmy.co/fabpackageb

Cam has built something pretty special. It’s one of the wildest ZN6s on the planet with a tube frame front and rear end, expansive cage, wild LS3 powerplant, custom cantilever suspension, and much more. The best part? Cam is only 22, and everything he’s done to this car — design, fabrication, paint, wiring, and more — were skills that he learnt himself using the power of the internet.

In this episode, we talk to Cam about how he became obsessed with the ZN6 platform in his teenage years (which wasn’t that long ago to be fair), culminating at 17 years old when he bought this very FRS as his first car. With Cam’s other main interest being art, he was able to transfer his creative side into the automotive world. We then jump into a full build breakdown on the Scion itself, in which Cam takes us through the whats, whys, and hows of the car. This machine went from your typical Rocket Bunny bagged-on-big-wheels 86 build to something worthy of SEMA glory, so there’s a lot to cover.

Cam also discusses wiring, design, and fabrication at length, covering his ethos behind many of the choices he made on the fabrication side, as well as a breakdown of all the tools he uses in his home garage — the total cost of which might shock you.

This episode shows you that you don’t have to be a professional in the industry or have the best gear in order to build top-level vehicles — you just need the right ideas, motivation, and a healthy internet connection. Let this conversation with Cam Cocalis provide the inspiration you need to get started.

Dont forget, you can use “CAM100” to get $100 OFF HPA Motorsport Fabrication Package: https://hpcdmy.co/fabpackageb

Follow Cam here:
IG: @cam.cocalis
YT: Cam Cocalis

Get the what, how and why on the 6.0L LS-powered Nissan Frontier, aka Navara from owner/builder Stephen Dorrick of @LOJConversions.

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

A 700hp+ 6.0L  LS engine owing around 6k USD powered this rather porky 4720lbs (2100kg) chassis to 2nd place in the GTT @optimabatteries Ultimate Street Car Invitational at @semashow. Build wise forged @MAHLEGroup pistons and @Lunatipower connecting rods are used along with @KingBearings engine bearings, ported LS3 head and aftermarket cams. The twin @BorgWarnerCorporate Airwerks  S257 SX-E run around 13psi but there is room to go up to 20psi on occasion thanks in part to the use of an E50 flavoured ethanol fuel blend.

A @haltech Elite 2500 manages the engine with an I/O expander to increase sensor inputs for a well set up and nicely prioritised engine protection strategy. This Nissan is AWD with the use of a TR6060 mated to a transfer case from a Chevy Blazer which gave Stephen an easier job of using the likes of a Y62 Patrol rear diff with that rear end seeing 70% of the torque split.

The LS retains a wet sump, however, it has been modified and an Accusump is fitted for extra insurance and with essentially only @vikingperformance2574 Berserker coil-overs fitted there are plans to upgrade much of the suspension components in the future to remove excess compliance as well as a focus on weight reduction.

Have you ever dreamt of climbing to the very top of your chosen motorsport and beating the world’s best? That’s exactly what Hayden Paddon, this week’s podcast guest, has done. As a past WRC round winner and current European Rally Champion, Hayden is a wealth of knowledge on all things rally, and spends some time in this episode talking through us through what life is like at the highest levels of the sport, what the future of rally might look like, and much more. 

Use “PADDON100” to get $100 OFF our HPA Track Day Package: https://hpcdmy.co/trackdayb

Born in a little town in the South Island of New Zealand, Hayden Paddon was introduced to the world of motorsport early thanks to his rally-driving father. Racing karts and rally events growing up, Hayden went from strength to strength before claiming the first of five national rally titles in 2008. Hayden then burst onto the world stage, becoming the PWRC world champion in 2011, and soon found his way into the big leagues with the factory Hyundai WRC team, claiming a hard-fought win in 2016’s Rally of Argentina.

For any driver outside of Europe to get a seat in a factory WRC team is impressive — let alone a round win. It sounds like a fairytale, but the reality is of course very different — it’s been far from all rainbows and unicorns, and Hayden opens up in this episode about just how hard the journey to the top is. And then staying there? Well that’s even harder still.

Hayden talks us through the various machinations, politics, and extreme levels of pressure at this elite level of motorsport — and this includes some really good advice around getting and, more importantly, keeping sponsors.

These days, when he’s not dominating the European Rally Championship, recently becoming the first non-European to win it, Hayden spends as much time back home in New Zealand as possible, developing his own take on the possible future of the sport in his Hyundai Kona EV rally weapon. Hayden breaks down the build, explaining how it all works and what advantages and disadvantages an electric vehicle has over the traditional ICE-powered rally car.

This episode provides a fantastic look inside the world of WRC, covering everything from the insane stress of leading a rally with a seven-time world champion only two seconds behind, to how a co-driver and driver relationship actually works, and much more.

*NOTE* At the time of recording, Hayden was yet to secure this year’s European Rally Championship.

Don’t forget, use “PADDON100” to get $100 OFF our HPA Track Day Package: https://hpcdmy.co/trackdayb

Follow Hayden here:
IG: @haydenpaddon
FB: Hayden Paddon
WWW: haydenpaddon.com

The legendary title-winning GT300 350Z Nissan hits the Time Attack scene. Get some insight into a factory race car setup including BoP restrictions & more in this [TECH TOUR].

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

Restricted to 300hp for class rules, this VQ35DE powered JGTC (Now Super GT) Z33 350z interesting sees up to 480hp due to some clever intake work by Nismo according to owner and driver Dale Malone of DM Motorsport with a maximum output of 580hp being a potential, but only for a short period of time mainly due to harmonics being an issue at high RPM.

The car runs an older Pectel Cosworth electronics package with Windows 95 still being the required OS to run the tuning software. While it's great to keep things original, complications like this are one of the reasons why we see many people update the electronics in older racing platforms in order to give more flexibility and even increase reliability with the modern crop of ECU's and sensors we have available nowadays.

One of the interesting aspects of this car is the 28l intake and airbox which allowed for an extra boost of power coming out of the corners before the intake restrictors, the size of which was dictated by the circuit back when it was a factory race car with teams having a range of engine maps to suit.

Common to motorsport applications a Hewland split shaft transmission which allows for individual gear ratio adjustment and a PI Research data logging system is in place however other than the general engine inputs for the World Time Attack Challenge, shock potentiometers are the only added extra for the moment along with a GT500 aero setup, GT500 being a less restrictive class in the same series at the time.

With enough effort and development time, where's the limit on how much power you can extract from an engine? On this episode, Mark Mazurowski of Mazworx is here to talk about his own experiences in doing just that with Nissan’s iconic 90s workhorse, the four-cylinder SR20.

Use “MAZWORX50” to get 50% OFF our HPA Engine Building Starter Package: hpcdmy.co/enginepackageb

Mazworx is a well-known name in the industry — particularly if you have an interest in imports, but prior to starting the company two decades ago, owner Mark Mazurowski was about as far from the Japanese performance scene as you could get — being way more interested in classic domestic muscle.

That all changed after enlisting in the US Marines, which eventually saw him posted to Japan, where he was exposed to the JDM sports car scene in what was inarguably its golden era of the mid-nineties. When the time came to leave, Mark was able to ship his personal S13 back to the States just in time to catch the explosion of US import culture. One mechanical engineering degree later, and Mark waded into the deep end by starting his own business.

In this episode, Mark talks about how Mazworx quickly became the go-to outfit for all things Nissan SR20, as well as the many business successes and failures he’s seen over the years and the lessons he’s learned along the way.

As we run Mazworx products on our own SR20VE-powered Toyota 86 endurance car, Andre couldn’t pass up the opportunity to pick Mark’s brain and extract plenty of hard-to-come-by SR knowledge. As you can imagine, this means the conversation goes way deep into Nissan’s best-known four-cylinder, and there’s a lot of wisdom to be found.

Mark also discusses his SR20 billet blocks, as well as his own drag car, which runs a 2000hp version of the billet motor and was once the world’s quickest and fastest four-cylinder. Times have moved on since, and the car is now sitting in seventh place… but there are plans afoot to take that record back by pushing boost way up to figures nearing 200psi, which should see somewhere north of an insane 3000hp using a compound turbo setup.

With some great insight into what makes a tuning shop actually profitable instead of perpetually treading water, as well as an interesting comparison between the SR20 and the new gold standard Honda K20, there’s a lot to chew on in this great episode of Tuned In with Mark Mazurowski of Mazworx.

Don’t forget, use “MAZWORX50” to get 50% OFF our HPA Engine Building Starter Package: hpcdmy.co/enginepackageb

Follow Mazworx here:
IG: @mazworx
FB: Mazworx Racing Engines
WWW: mazworx.com

This 1973 Datsun 240Z (S30) is an excellent example of modernising an older vehicle for competition motorsports, and still driving it home afterwards complete with aftermarket ABS!

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With double the stock horsepower via a 3L Nissan L28 with custom pistons, rods, cam, and a ported N42 head care of Datsun Spirit Inc, Darren Garvin's 240Z (aka Nissan Fairlady Z) was a standout from the crowd at the 2022 OPTIMA street car challenge.

An Electromotive electronics package has been utilised to help take the car from its factory 150hp (at the crank) carbed output to 300hp at the wheels, with the ATI harmonic damper holding a hall effect trigger setup and the TPS and MAP sensors being used as load inputs and a Jenvey Dynamics 50mm ITB setup on intake duty. Also discussed are other considerations around a carb to EFI conversion.

A faster car needs better brakes, with the factory setup, including drum brakes on the rear, being retired in favour of an Arizonzacar brake package that includes Willwood 4 piston callipers and 12.5" rotors. The car also utilises an ABS system from an E46 M3 BMW, and Darren runs us through the requirements, including yaw, pressure and speed sensors.

The drivetrain sees a 240SX gearbox mated to a 280Z bell housing, Quaife diff and CV axles to put the power to the ground, and a shortened driveshaft and Techno Toy mount kit to help get and keep it all in place.

With most owners ditching their L series in favour of an RB26 or LS V8, it's nice to see this 240Z chassis simply modernised vs radicalised and with 40-50hp more as planned, this car is undoubtedly going to be even more of a weapon on track.

There’s no denying that the C6 Corvette is an excellent sports car platform, but it’s probably not the first option that many people reach for when looking to put together an ultra-competitive top-level time attack car. Feras Qartoumy clearly understands its potential, though. He’s not only built a competitive Corvette — he’s built an absolute monster that doesn’t just take podiums, it smashes plenty of outright lap records too.

Use “FERAS100” to get $100 OFF our HPA Track Day Package: hpcdmy.co/trackdayb

If you’ve been following time attack in the US at all, Feras Qartoumy is a name you’re probably already familiar with. Along with his trusty Corvette, Feras has set and reset many lap records on circuits around the US, consistently proving to be the man to beat.

In this episode, Feras first talks us through how he built up the skills he uses to build and improve his rapid Corvette, before diving into his racing history that started with karts and pro-touring muscle cars.

The sport of time attack is next on the table, as Feras breaks down the format, explaining how it all works and the differences between time attack in the US versus locations like Australia and Japan.

The conversation next dives deep into Feras’ dominating twin-turbo C6 Corvette. All aspects of the car are broken down and explained, from the powerplant to the suspension, to the aerodynamics package, and much more. Feras goes into an excellent amount of detail in explaining why he made the decisions he did when putting this build together, and just why he thinks the car is as fast as it is. To be clear, although this definitely isn’t a super cheap build, it’s also not an open-chequebook project either, and there’s some great insight in this episode when it comes to getting the most speed out of your dollar.

This conversation also covers the centrifugal blower vs turbo argument, building engines for time attack racing, motorsport traction control, how Feras fabricated his own aero package for the car, and a whole lot more.

With the Corvette currently on its way to Sydney for this year’s World Time Attack Challenge, we’re looking forward to seeing just what this all-American record-breaking machine and its driver can accomplish on a world stage.

Watch our SEMA 2022 interview with Feras here: youtu.be/xhcPXKrw1aw

As mentioned, you can listen to our episode with Andrew Brilliant here, and our episode with Paul Lucas of Verus Engineering here.

Don’t forget, use “FERAS100” to get $100 OFF our HPA Track Day Package: hpcdmy.co/trackdayb

Follow Feras here:
IG: @feras_qartoumy
YT: Feras Qartoumy

What do you know about rocket antilag systems? Not much? Good, you're going to love this then.

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

Sporting a 1200hp LS7-based engine, Mike DuSolds 1967 Chevrolet Camaro has been 'slightly' modified for competition motorsport anywhere from sea level, to 14,000ft (4,300m). Time attack, hill climbs, street car challenges, this car does it all and more. With power at altitude a major focus of the current specs, the Dart Machinery block, 6 bolt GM Performance Parts LandSpeed Developments ported cylinder head and Shauns Custom Alloy intake are just a few parts that help the car produce torque low down and keep the 88mm Garrett turbo forcing air as it should. A MoTeC ECU is used with a custom Motorsport Electronics firmware package is used to control this race cars somewhat unique setup.

Some clever suspension design and adjustment points which allow quick motion ratio changes that don't impact on overall car setup is just one feature the custom tube framed chassis offers with a transaxle rear (SADEV and Corvette combo) and approx 1450kg total weight.

Mike also gives a great explanation on camber gain and their prototype/simplified rocket antilag system (ALS) that has been so successful there has been no need to produce the 'real' version just yet with some more testing and insight required to understand what makes what shouldn't work on paper amazing in reality. Another surprise discovery in the quest for peak performance racing up the side of a mountain was the exhaust size and pressure ratios seeing the setup run what a N/A engine normally would with again the real data tearing up the notebook.