Bouncing off rocks the size of houses and pinning it through the unforgiving desert at maximum speed, the vehicles competing in California’s King of the Hammers race have to be the absolute toughest in the world — all while still being fast enough to be competitive. After interviewing Sam Dobry of Dobry Designs recently at SEMA, we knew we needed to get him on the podcast so we could dive much deeper into this brutal form of motorsport.

Use ‘DOBRY25’ for 25% off our HPA Motorsport 3D Modelling and CAD course here: https://hpcdmy.co/cadb

Sam specialises in designing and constructing high-end 4400 Ultra4 Class race trucks — this isn’t a form of motorsport that a huge amount of people have a good understanding of, so this conversation has been an enlightening one.

We first dive into exactly what’s involved in this form of competition, which is essentially a mix of two polar opposite disciplines — high-speed desert racing and extreme rock crawling. This presents some unique challenges when it comes to creating a vehicle that can do both things well, as they each require very different abilities.

What is universal, though, is the need for extreme levels of strength, performance, and reliability, and with an attrition rate of around 80 percent each year, the King of the Hammers event is designed to break even the toughest engines, drivelines, and suspension. Building anything to take this sort of punishment and make it across the finish line while still being fast enough to get there before everyone else is a unique exercise in mechanical engineering, and Sam has some very interesting takes on everything from engine building, to chassis design, to diff and trans longevity.

This conversation also covers how Sam got into this line of work, his thoughts on 3D modelling and validation, working with Chromoly steel, heat treatment, proper TIG welding techniques, and much more.

Follow Sam here:
IG: @dobry_designs
YT: @genrightoffroad

Don’t forget, you can use ‘DOBRY25’ for 25% off our HPA Motorsport 3D Modelling and CAD course here: https://hpcdmy.co/cadb

What spring rate should I run? How should I adjust my bump and rebound damping? And how low is too low? We’re always getting asked the same questions when it comes to suspension, so on this episode of Tuned In, we sit down with KW Suspension’s Head of Motorsport Thomas Rechenberg to get some definitive answers from someone who knows his way around a coilover, to say the least.

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

Thomas Rechenberg grew up a mere 50 kilometres from the Nurburgring, and after spending his youth watching all kinds of motorsport at the fabled track, the question of what to do with his life was an easy one.

We kick off this episode by following Thomas’s trajectory as he left school to study mechanical and motorsport engineering before joining famous teams like Zakspeed and VW Racing to work as a tyre technician, a race mechanic, and a specialist engineer. With this sort of resume, podcast host Andre couldn’t resist getting Thomas’ opinion on subjects like tyre heat management and pressure before moving on to the meat and potatoes of the conversation — suspension.

After a stint going out on his own as a gun-for-hire race engineer, Thomas joined KW as its head of motorsport back in 2018, and has since helped develop the company’s race car programs and motorsport-focused coilover offerings. This means he’s the perfect person to get right down into the weeds of suspension, breaking down his thoughts on everything from spring rates, damping, roll centres, and much more.

Thomas also spends time talking us through how the everyday home enthusiast that doesn’t necessarily have access to high-end data-logging equipment or advice from professional drivers and engineers should go about initially setting up and tuning their suspension systems.

Ultimately, how quickly you can drive is always going to come down to the contact patch between your four tyres and the track surface. Suspension plays a massive role in how big that contact patch is at any given time. Want to get a better understanding of suspension systems? This episode of Tuned In with KW’s Thomas Rechenberg is going to be the perfect way to spend a couple of hours.

As discussed in this episode, check out images of the Porsche 963 rear suspension system here: https://hpcdmy.co/963

Follow Thomas and KW Suspension here:
LI: Thomas Rechenberg
IG: @kw_suspension
FB: KW Suspension
WWW: kwsuspensions.net

Has this conversation inspired you to improve your own car’s handling? Use the discount code ‘THOMASKW50’ to get 50 percent off our Suspension Tuning & Optimization course: https://hpcdmy.co/alignb

What makes this 1300hp V8 time attack machine tick?

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

With 780hp at 8psi low boost and 1300hp at 20psi high boost (that's 969kW at 1.38 Bar) options on tap via 2 externally-ish mounted Garrett G35-900 turbochargers and an LME-built, 430ci LSX, Feras Qartoumy's C6 Z06 Chevrolet Corvette is no stranger to a trophy or two as discussed at SEMA.

The LSX is a 2000hp spec build using an RHS block, Callies crank, rods, Diamond pistons, Brodix head, a custom-ground camshaft from Comp Cams, and an MSD Atomic Airforce intake manifold. Part of building up to this level over the years involved using a lot of aftermarket parts that would support the required power levels, but were more suited for drag racing and dyno queen runs (no offence intended!), leading to some unexpected development requirements all for the better.

The car uses a MoTeC traction control system via the M150 ECU to help keep the full boost from 3500rpm under control, and a Bosch Motorsport ABS system at the other end of the straights which has had the biggest impact on car confidence so far.

So what next? One of the biggest future goals is to reduce weight. To get where it is at 2950lbs (1228kg) other than general parts stripping, the car has shed 40lbs thanks to carbon fibre body panels from Anderson Composites and a whopping 60lbs from the removal of the stock wiring harness some years ago. Adding a paddle shift setup to the PPG 6-speed sequential is also high on the list along with suspension data solutions and some tidying up of the impressive Verus Engineering & Feras developed aero package.

At the time of filming the car holds at least 22 track records.

Want to learn how to tune EFI? Start here instantly, and for free: https://hpcdmy.co/tuneb

Eight-point-something litres, 10 cylinders, one camshaft, and a whole lot of noise — the Dodge Viper is as weird as it is cool, and in this episode of Tuned In, we’re joined by Viper-specialist Mike Kuchavik of Havik Performance to dive deep into this unique piece of engineering to get the truth behind America’s poster-worthy supercar and it’s brutish V10 motor.

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

Havik Performance specializes in all five generations of the Dodge Viper platform, which makes it a fairly niche business, but this has allowed Mike and his team to build up a loyal customer base of Viper owners, as well as an in-depth knowledge in this most American of supercars.

In this episode, we explore Mike’s path to opening Havik Performance in Pennsylvania at a fairly young age, as well as his early love for Chrysler’s supercar that would go on to become his bread and butter later in life. As you’d expect, we’re also able to take a good look at the different generations of the Viper and discuss all their pluses, minuses, foibles, and limitations — including some in-depth discussions around the car’s famous V10.

Although part of Mike’s day-to-day involves looking after private Viper collections upwards of 60 cars, he doesn’t stop at just general maintenance, so the conversation naturally covers the modification and tuning of the Dodge V10 — whether that be staying NA and focusing on headwork and cams, or going nitrous, turbo, or supercharger — Mike and his team have built and tuned them all and have plenty of insight to give.

With some good discussion around aftermarket standalone ECU vs reflash for the Viper, as well as the challenges that working within such a niche realm and at such a young age present, this episode with Mike Kuchavik of Havik Performance is well worth a listen.

As mentioned, check out our episode with John Reed: https://hpcdmy.co/johnreed

Follow Havik Performance here:
IG: @havikperformance
FB: Havik Performance
YT: Havik Performance
WWW: havikperformance.com

Interested in learning to build your own performance engine? Start here: https://hpcdmy.co/engineb

Sam of Dobry Designs runs us through this @GenRightOffRoad 600hp LS7 powered Ultra4 racer built for one of the toughest offroad racing events on the planet, King of the Hammers. KOH sees vehicles race at opposite ends of the offroading world at the same time seeing speeds over 100mph across open desert into rock sections that see vehicles doing single-digit speeds, or sometimes even less as they hit reverse to try another line or drive around (sometimes even over) a struggling competitor.

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

In this [TECH TOUR] via the @semashow @TorcoUSA stand Connor & Sam discuss:
- What is KOH?
- Cooling for desert racing
- Design fundamentals including 'Rod Ends In Bending' explanation (REIB)
- Oil pressures vs parts reliability and longevity & damaging oil vapour
- Full independent suspension vs solid axle for KOH
- Drag radials as 40" offroad tyres
- Massive ground clearance without the height/COG (center of gravity) issues
- Tyre construction & weight gives huge advantages for mixed terrain & speeds

BUILD BASICS:
600hp LS7 based engine with @EdelbrockTV  RHS  tall deck, All Pro heads, @Compcams1976  COMP cams & Johnsons High Tech Performance driven dry sump system.
Custom Griffin radiator, oil cooler only for summer racing.
Turbo 400 transmission, spool rear one way locker front using Tubeworks 9.5" fork style differential & @AdvanceAdapters1971 Atlas transfer case.
4-wheel independent suspension, double wishbone with a 5-link rear.
Portal axles allow 3:1 diff ratio for high-speed section advantage and less CV breakages
40" @mickeythompsontires Baja Boss tyres on 17" rims.

For more KOH & offroad racing content (thanks for the footage too team!) check out: @jordanpellegrino @jamipellegrino @jordanpellegrino3867  & of course Genright Offroad and Mickey Thompson.

Want to learn how to tune EFI? Start here instantly, and for free: https://hpcdmy.co/tuneb

How useful are flow bench numbers? Should we be mirror-finish polishing our ports? What about adding dimples like a golf ball? On this episode of the podcast, David Localio of Headgames Motorworks joins us to dive deep into one of the most misunderstood areas of the performance automotive world — cylinder heads.

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

David Localio of Headgames Motorworks is best known for building and developing some of the fastest import cylinder heads anywhere in the world. He’s able to do this thanks to two decades worth of experience in the game, as well as a healthy passion for making anything on four wheels go faster.

We first learn about David’s early years, in which he saved up his paper run money to buy his first muscle car at 12 years old (then subsequently got that car taken off him after driving it around the neighbourhood one too many times), then jumping into the street racing world before eventually finding his true passion through both an education and hands-on experience at some renowned engine building shops.

After soaking up all that knowledge, David then started New Jersey-based Headgames Motorworks, where he continues to hone his craft, all while building heads for some of the best-known and decorated import cars in the world.

Head porting is an area that seems to suffer — or benefit, depending on how you look at it — from a crossover between science and art, so much of this conversation is spent getting into the finer details of many aspects of head work, from port and polishing, to valve grinding, cam selection, and much more.

David has some very interesting non-conventional views on what works well and what doesn’t when it comes to headwork, and while any ordinary person might have those controversial opinions dismissed by the masses, this is a guy with the results, the records, and the trophies to back it all up. This is one episode of Tuned In NOT to be missed.

Follow Headgames Motorworks here:
IG: @headgamesmotorworks
FB: Headgames Motorworks
YT: Headgames Motorworks
WWW: headgamesmotorworks.com

Interested in learning to build your own performance engine? Start here: https://hpcdmy.co/engineb

CU,  PDM, datalogger, oscilloscope and a wideband controller, all in one unit that now fits in your pocket. It's not for your pocket flex game though, so let's take a look at what the NEXUS R3 is aimed at accomplishing for you.

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

We've talked about the Haltech NEXUS R5 VCU (vehicle control unit, a fancy term for 'many features in one') before and are excited to see a baby brother at a lower price point soon hitting the market as discussed with Anthony Truong from Haltech.

The R3 uses RadSok power connectors, 1 x Deutsch DTP connector for the PDM side of things, 2 x AMP Superseal 1.0 26-pin connectors, WiFi antenna port & a USB C data connection that we love seeing here as much as we did on the R5 (great for gloved hands on race day!).

So who is this for? Maybe you? If you are running a high performance 4 cylinder with some common bells and whistles like staged injection, the R3 is going to handle this for you along with a V8 setup that has one injector per cylinder and it retains the same functions as the R5 when it comes to advanced tuning options like torque management, nitrous control, race timer, flat shift and closed loop boost control. It does this while also controlling your engine electrics and drive-by-wire throttle system keeping the wiring simple and more affordable depending on how your accountant looks at these things.

This is all controlled via one piece of software, which like the USB C port is a nice touch for ease of use, especially when in a rush at an event or leaving a hand free to grab a beer instead of hovering over Alt+Tab keys.

Want to learn how to tune EFI? Start here instantly, and for free: https://hpcdmy.co/tuneb

From fighter jets to JDM icons.

In this episode of Tuned In, we speak to Josh Ray of Driver Motorsports, who left a 20-year-long career in the US Navy as a fighter jet technician to follow his passion, pouring all that military experience, attention to detail, and knowledge into a new career building and tuning the ultimate Japanese legends for a living.

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

Josh Ray always wanted to build and tune cars, but after leaving school at 17, he couldn’t afford to pay for the education or equipment to make that dream a reality. Do you know who’d gladly pay for it though? The US military.

Josh joined the Navy and worked his way up to Senior Chief, responsible for the maintenance and repair of fighter jets like the F14 Tomcat and FA18 Super Hornet. Along the way, he was given huge amounts of training and experience — far more than you could ever hope to get in the civilian world — that would put him in perfect sted for when the time came to leave the Navy and work with high-powered JDM icons.

In this episode, Josh discusses how he transitioned away from the military and joined Driver Motorsports, where he builds everything from engines to full car projects, as well as manning the laptop in the dyno bay *spoiler alert* our own High Performance Academy courses had a part in filling any knowledge gaps he had.

Josh has always loved 90s Japanese cars, so the conversation naturally turns towards stalwarts of the era — specifically Nissan’s Z32 300ZX and R32 GT-R — in an attempt to separate hype from reality. Josh owns both, so he’s more than qualified to weigh in on the subject.

With some great conversations around buying cars at Japanese auctions and then importing them into the States, the ins and outs of road tuning, and minimising dyno result inconsistencies, this conversation with Josh Ray is well worth a listen.

Follow Driver Motorsports here:
IG: @drivermotorsports
FB: Driver Motorsports
YT: Driver Motorsports
WWW: drivermotorsports.com

Interested in learning to build your own performance engine? Start here: https://hpcdmy.co/engineb

Running an R32 GTR transfer box off the back of a Holinger RD6, Winters Quick Change rear differential, Haltech R5 NEXUS ECU/PDM,  Garrett 94mm OR 106mm turbo, Clearview oil filtration system along with Ti Automotive a dual brushless pump setup among a long list of other parts, we caught up with Rob Dahm at @semashow to discuss his ever-evolving and now essentially complete FD RX7 quad rotor build.

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

The Haltech R5 doesn't just handle engine management; the built-in PDM also controls many of the electrical components leaving the car without fuses or relays. A standalone ECUMaster PMU splits this duty in 2 adding redundancy plus more inputs and outputs. A FuelTech FTSpark Capacitive Discharge Ignition (CDI) also helps in the ignition department. Interestingly this build draws up to 80amps, and as you can see (and hear) Rob has made sure that isn't an issue with this setup.

Traction control is also handled by the Haltech R5 via a Nissan ATTESA-based control system and some 'fettling' by Rob which allows him to demand a dynamic or set torque ratio between the front and rear of the car allowing for versatility when launching and cornering across many surface conditions. We also touch on some Nikasil-style coating that is used to make sure aluminium and steel alloys play together nicely. Interestingly the engine is clearanced specifically for Valvoline 20-50 oil which shows the level of detail this build has reached. 

The long list of topics continues with Precision Engineering eccentric shafts, rotary irons, apex seals, 16-point total TPMS (tyre pressure monitoring system) and the gremlins auxiliary systems can cause a rotary engine.

Last time we spoke to Rob he mentioned his interest in more A-B testing, and he has followed through on this and discussed some poor injector placement and cooling issues that upon investigation and data collection he has resolved often by taking it upon himself to learn the skills to do the job himself. Machine work, wiring and tuning are just a few skills he has picked up as a direct result of this build.

Want to learn how to tune EFI? Start here instantly, and for free: https://hpcdmy.co/tuneb

David Higgins of Kinetic Simulation and Classic Revival drops into the podcast this week to give us some insight into creating no-holds-barred bespoke race cars from scratch, modernising and racing iconic motorsport legends, and owning and running your own real-deal Formula 1 car.

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

David is probably best known for his work in motorsport engineering and aero design, but that’s just scratching the surface of what he gets up to on a day-to-day basis.

To find out more, we first look back at David’s journey from his early days spent racing his Dad’s classic Porsches and Formula cars, to getting a mechanical engineering degree at university, to eventually finding his feet, taking a punt, and starting his own motorsport design and engineering firm, Kinetic Simulation.

This has meant David’s had a hand in designing and testing plenty of fast projects, and time is spent in this episode discussing how simple aero enhancements have shaved seconds off his client’s cars.

We also take a detailed look at one of David’s most extreme projects — a modernised replica of a BMW E21 Group 5 race car, developed in collaboration with Kiwi company RaceLab. The project has gone through various iterations on its journey to where it is now as a full carbon fibre monocoque weapon with a stressed-member V8 and transaxle setup that should prove stupidly fast when finished.

While motorsport design, FEA, and CFD testing do play a big part in David’s day-to-day duties, there’s also the Classic Revival side to the equation. This is a family-owned group that David, along with his father and brother, use as an outlet for their passions — namely sourcing, restoring, and running motorsport icons of the 80s and 90s.

These include a GT300 Mazda RX-7, a Group C Porsche 962, and a couple of Leyton House Formula 1 cars — the latter of which we get into the nitty gritty of, discussing what the restoration process was like, what they’re like to work on, and what it takes to actually get them fired up and ready for a track session.

Follow David here:
IG: @aero_dave
FB: @Kinetic Simulation, @Classic Revival
WWW: kineticsimulation.com

Want to learn how to design and model parts for your project car? Start here: https://hpcdmy.co/CADb