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Progress
is inevitable, but sometimes it catches you unawares. This month's Tech
Focus subject, the S1100 Saxon Suzuki hillclimber, makes the 360kg,
130bhp 1100cc class hillclimber I drove some years back look like a
Neolithic hearse. The S1100 boasts 190bhp in 208kg. That's over 900bhp
per tonne already with the target of 1000bhp/tonne achievable with a
little more development.
The S1100
comes from the CAD screen of Norfolk based Prototype Car Designs (PCD),
run by ex-Lotus F1 chief designer Martin Ogilvie who also designed the
Westfield FW400 carbon sportscar. Driver Rob Barksfield has co-ordinated
engine development in a partnership hatched at a chance meeting at last
year's Autosport International Show. That the two should meet when one
had designed a carbon hillclimber and the other wanted to graduate to
one is spiooky. But fate or coincidence, the pair have taken full advantage
of the opportunity. CCC got the chance to get under the skin, and into
the mind of the designer, of the S1100 Suzuki before it even turned
a wheel on a track. The Saxon moniker, by the way, is a sort of unoffical
name Rob came up with.
LIGHTWEIGHT
TUB
To make
a car this light, the chassis also had to be light. To achieve the necessary
structural properties required to make the car work and keep the driver
safe, Ogilvie chose to use a carbon/honeycomb composite. Although the
tub weighs a mere "15 to 16kg", Ogilvie say: "it is in
fact of sturdier construction than the early composite construction
Formula 1 cars." A posssibly unique design feature is that the
chassis extends over the top of the engine, connecting the stiff rear
bulkhead. Ogivie wanted to only semi-stress the engine, so some kind
of rear chassis structure was needed, but to keep the frontal area of
the car small he didn't want structural sides around the engine bay.
Furthermore, the roll hoop had to be pretty sturdy to comply with the
regulations, and as he didn't want lots of weight high up in the car
he decided to make the roll hoop as small as he reasonably could and
take the chassis up to it. then, with the carbon chassis at that height,
it was a small step to extend it over the top of the fairly low engine.
So, you
ask, how do you get the spark plugs out? Answer: you fit good, reliable
ones, and hope you don't have to remove them in a hurry. It's a calculated
gamble; if you are unlucky enough to encounter a top end problem it's
unlikely to be just a plug gremlin, and you'll be taking the car back
to the workshop to fix it in any case. That said, it's a quick job to
remove the rear end of the car should that prove necessary. For most
of the time this is one of those compromises that won't be an issue...
hopefully. Ogilvie made four or five wooden chassis mock-ups early in
the project to make it as comfortable and small as possible. And the
need to only carry a small fuel tank for hillclimbs enabled the chassis
to be tapered in behind the driver's backside. As he says: "Why
have a chassis that's bigger than the driver?" The chassis taper
has been shaped to channel cooling air to where it is needed without
adding width to the car. We'll explore details later in the aerodynamics
section.
Other safety
features include what Ogilvie calls "a proper carbon/honeycomb
nose box", and the raised nose has enabled him to locate the lower
wishbone mounting underneath the chassis. He says"This is something
I've wanted to do on any cars I do myself. I'm paranoid about having
the rear leg of the lower wishbone going into the driver's legs, which
you can always have if they're going through into the chassis or a bulkhead.
I wanted to put then underneath so in a shunt they shear off and the
driver stays intact." Ogilvie also says the car will also be suitable
for circuit racing because it has the regulation cockpit opening for
the driver, the corrent size roll hoop, the front crash structure -
every thing you need for MSA approval for racing. And here's another
nugget for you - the S1100 was originally conceived as a two pedal car.
The extra (clutch) pedal has been squeezed in for now whilst the car
is sorted but a sophisticated paddle-operated gearshift mechanism with
hand-operated clutch is under development....
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POWER
PUNCH
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CCC
has propounded previously on the benefits of bike engines
- lightweight all-alloy units producing high power outputs at
high rpm. The Suzuki GSX-R motor, though no longer current, is
one of the more popular choices for powering small racecars because
of the availability of engines, tuning parts and expertise. And
the S1100 was designed specifically around the GSX-R 1100 motor
because its carbs are side draught (which fitted with the over
the engine chassis concept) most other bike engines having more
of a down draught angle. Slight over-boring to 75.9mm with standard
60.0mm stoke give 1086cc swept volume. In current specification
it produces around 190bhp at the crank at 10,000rpm. That's pretty
respectable 175bhp per litre.
Rob
Barksfield's engine is prepared by Ray Debben, at Debben Performance
in Ringwood, Hampshire and Ray outlined some of the tuning background:
"It's basically about blueprinting and parts selction. We've
taken weight out of the crank and pistons and so on, and we've
also had the luxury of about 50 dyno runs in which we tried all
manners of ideas with carbs, cam timing, ignition curves and so
on. With the head the trick is to do surprisingly little - basically
we've found what not to do. It's all about removing little bits
from the right places to induce tumble rather than high gas speed,
then you don't need big carbs." The engine uses flat-slide
Keihin 39FCR carbs - "good for mid-range power" - but
Ray says that fuel injection is on the development list.
"There's
a lot of expensive set up work to do though. With carbs there's
about 100 years of experience available, and I've got over 30
years myself, so we know what to do with them." But he says
he wants to get into fuel injection and reckons the MBE ignition
management system, new on the engine this year, has helped boost
performance from 6000rpm and upwards. The engine is wet sumped,
partly because of the extra weight of a dry sump system. Ray reckons
that the engine runs so little oil in its shallow sump that the
windage losses are small enough not to worry about. Weight was
the over-riding issue, and with other savings made from lightening
(knife-edging and polishing) the crank, not running a starter
or the attendant gears and starter ring, or an alternator, and
using a lighter electrical loom, the weight of the engine and
transmission less carbs and exhaust is just 62kg, The exhaust
is made in 30thou (0.76mm) wall thickness ceramic-coated mild
steel so it isn't exactly heavy either.
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SUSPENSION
AND WHEEL SYSTEMS
Suspension
is by double wishbones and pushrods all round, with a 'monoshock'
at the front and dual spring/dampers at the rear. The front spring/damper
system isn't really a monoshock because within the small anti-roll
coil springs there is a separate damper to control them, as well
as the usual one within the larger bump/pitch spring. There is
no separate anti-roll mechanism at the rear. The dampers are re-valved
Formula Vee units and are non-adjustable. On suspension design
Ogilvie says:"I've basically gone for fairly standard geometry
and I've allowed more movement, especially in roll." The
narrowness of the car means that the inboard suspension pick-ups
are on a narrow base, which means the wishbones are pretty long.
Longer wishbones give less wheel camber change for a given amount
of wheel movement, keeping the tyres flat on the road. Ogilvie
reckons: "If you've got good roll centre control, correct
camber change, correct weight distribution and good roll centre
heights the car will handle anywhere." There is a modicum
of anti-dive at the front and (adjustable) anti-squat at the rear
built into the geometry. Ogilvie's not a fan of too much of either
parameter because they deaden feel and have other adverse effects
but he acknowledges that some can be advantageous. There is also
Ackerman angle built into the steering (to steer the inner wheel
on a tighter radius), beneficial where there are tight corners.
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Weight-saving
ideas abound on this car, but are more visually obvious in the brakes
and wheels. The brakes basically come from the rear of the legendary
Italian Ducati bike marque, though the diminutive two-pistons alloy
calipers are sourced direct from Italian manufacturer Grimeca. The drilled
discs are in nitrided stainless steel, held on by the slightest of alloy
disc bells. Even the hydraulic components are minuscule, again from
the rear of the Ducati. If all this seems under-engineered, remember
the car weighs little more than a bike, yet uses four brakes and four
sticky tyres to stop. Ogilvie says there were two reasons for the unusual
location of the discs, inboard of the uprights. "Fiirstly, if you
sandwich the wheel bearing directly between the discs and the wheel
then you don't need a hub [which saves weight]. And secondly I had anticipated
making the wheeels out of two symmetrical spinnings bolted back to back,
and that didn't allow room for the usual pisitioning of the caliper
and isc. But nobody could make the necessary spinnings economically
so I decided on machined-from-solid wheel centres." The rims are
spun and with those minimalist centres they still make for extremely
lightweight wheels.
The suspension
components are attached by 1/4-inch bore x 5/16-inch shank rod end bearing
or 1/4-inch bore spherical bearings connected to almost dainty-looking
machined steel brackets. Again it all looks small than we're used to
seeing. Ogilvie agrees: "That's right. You've got to re-train your
engineering eye and say 'hang on a minute, it's less than half the weight
of an F3 car, so it has to take less than half the loads.' There's a
lot of sayings I go back to Colin Chapman for, such as ' a quarter inch
bolt will lift a double-decker bus!' We don't have a double-decker bus
so we don't even need a quarter inch bolt!"
The choice
of tyre size was one area where Ogilvie succumbed to convention. Avon
recommended 8-inch wide front and 10-inch rear yres because they are
well developed. Ogilvie says: "F3 sizes look right, but I would
like to try them smaller (and lighter)." The tyres were designed
for a 450kg F3 car and do seem disproportionately heavy for such a light
car. But with the three-piece wheels, some different rims could be spun
to allow narrower tyre to be tried if required. The steering was definitely
not compromised, a hard-anodised hollow aluminium steering rack being
made by Tian to save a chunk of weight compared to the usual steel bit.
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LITHE
BODY
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As long as driver of single seater have to sit at least slightly
upright, there will be a practical minimum frontal area. The S1100
chassis/body is just about down to that minimum, which together
with the sleek shaper should ensure minimal drag. As mentioned
earlier, the radiators are tucked in almost behind the driver's
backside. The car was originally going to use the oil-cooled Suzuki
engine, which needs plenty of air to cool it too, hence the scalloped
sides to direct air at the engine block. Following the descision
to use the water-cooled engine, those scallops enabled twin radiators
to be used without adding much to the car's frontal area.
Low
drag from the body is significant when it comes to how much wing
the car can carry. Front wings do not add significant drag but
rear wings do and the low body drag allows a reasonably powerful
two-element rear wing without undue concern over the induced drag.
This will obviously provide a fair bit of downforce. To balance
that, the front wing, slung under the nose via a shapely carbon
moulding, is a fairly large single element device. Ogilvie says
they've started with a basic aero package but developments will
continue. "Because we've got no sidepods and it's a narrow
car we've got a lot of scope along the side and at the back to
put what we like. You want to produce downforce and the right
distribution (front to rear). That's where we require a bit more
research. Ground effect aerodynamics depend on constant ride height,
and you don't want an aerodynamic package which is sensitive to
the variations of ride height you have on a hillclimb.
But
as Ogilvie was a part of the team at Lotus, with Colin Chapman
adn Peter Wright, who first properly expolited ground effect on
a single seater (on the Lotus 78), expect him to come up with
somthing effective.
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CHAIN
GANG
Some
purists do not like the idea but chain-driven, bike-engined racecars
are quick and are therefore here to stay until a faster alternative
appears. It is possible to connect a bike to a conventional gearbox
or transaxle but it's a lot heavier than using the integral transmission
and chain drive. Thus the uprated GSX-R multi-plate wet clutch drives
the output sprocket, and via the short DID X-ring chain, power is transferred
to the alloy final drive sprocket. So far, pretty conventional.
The
diff however is a bit special. Martin says he didn't want a conventional
diff with a spocket grafted onto the side feeding out to CV joints.
His solution comes of a Fiat unit which CV inner flanges also serve
as the diff sun gears, an elegant weight-saving design which fitted
Ogilvie's requirements. It's acutally an X1/9 diff with an LSD. The
steel outer case is a bespoke machined item, shaved to the minimum (and
to be replaced by an alumimium case later). It's a neat looking solutuion,
though Ogilvie admits to some apprehension about the loads imposed by
dummy starts and sticky tyres even with a lightweight car. As he says,
you don't know until you try...
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SPARTAN
OFFICE
The
moulded cockpit is so full of impressive composites detail work
that you don't notice the lack of instruments beyond the Alpha
steering wheel. Who needs 'em? Not Rob Barksfield, or several
other hillclimbers these days. Apart from checking the engines
warm and setting revs at the start-line, hillclimb drivers rarely
look at the instruments, and probably never during an actual run.
So that's a few hundred grams more weight saved.
To
assist the timing of gear changes Rob has a bleeping earpiece
in his crash helmet, an aural shaft light if you will, that tells
him when he arrives at shift rpm. It's less distracting than a
system which relies on vision - particularly in a demanding competitive
environment like hill climb events when drivers have little time
to peer down at the instrument panel. Currently a lever and cable
on the left side of the cockpit operate the six-speed sequential
manual gearshift.
Rob
is to get a custom-moulded carbon seat soon so the car is going
to feel like it's a part of him. All single seaters are like that
but the low weight and compact dimensions of the Saxon makes may
others seem like pantechnicons [one for the dictionary lovers
there - Ed].
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PERFORMANCE
AND COST
The
S1100 has yet to turn a wheel under its own power as I write,
so performance can only be guessed at. But its power to weight
ratio without driver is almost in the same ball park as the unlimited
capacity hillclimb single seaters like the ex-F1 V8-powered Goulds
and Pilbeams, and well ahead of even the lightest 2-litre-powered
hillclimbers. In the 1100cc class the lightest competitor is maybe
40kg heavier, giving the Saxon a driver-aboard power to weight
ratio advantage of 14 per cent, assuming similar power. Providing
grip, handling and reliability are adequate, performance should
be highly competitive. If it grips and handles well, watch it
fly.
As
for cost, Ogilvie reckons the first S1100 rolling chassis stands
him in at £28,000 including parts, pattern and moulds but
not including labour. So you could reckon on paying somewhat more
than that if you wanted a replica. He aims to get the first car
developed into a competitve and reliable package first, though
he is considering the possibility of making more.
With
the S1100 taking on the already developed and rapid Force (which
is also running in the 1600cc hillclimb class and in Monoposto
on the circuits, and with another carbon-chassis racer still to
come from DJ Racecars, hillclimbing is a fascinating hotbed of
technical ingenuity at the moment.
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TECH
SPEC
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S1100
Suzuki Saxon hillclimber
Chassis:
Carbon fibre composite monocoque
Weight:
208kg
Engine:
Suzuki GSX-R, transverse mid-mounted, prepared by Debben
Performance. 1.1-litre straight four, four valve per cylinder,
DOHC, 190bhp at 10,000rpm, Keihin carbs, MBE ignition
management, Suzuki/Rob Barker/Electron Beam Processes
crankshaft, Carillo conrods, Wiseco pistons, Yoshimura
cams, APE valve gear, Tony Green exhaust, wet sump lubrication
system
Transmission:
RWD, Suzuki/APE/Goodrick wet clutch, Suzuki/Graham Dyson/Nova
Racing Transmissions six speed, manual, sequential gear
set, B&C Express DID X-ring chain, Fiat LSD, Titan
driveshafts, GKN Tripodes
Suspension:
Front: double wishbones, monoshock spring damper with
separate anti-roll springs and damper. Rear: double wishbones,
dual springs and dampers. Penske dampers
Brakes:
Grimeca two-piston calipers, 240mm x 4mm nitirded stainless
drilled discs, cockpit adjustable bias.
Wheels:
Alloy three-piece by PCD/Mike Barnby Engineering, 8 x
13in front, 10 x 13in rear
Tyres:
Avon soft compund, 7.2/20.0-13 front, 9.2/22.0-13 rear
Fuel
tank:
1.3-litres
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SBD
Motorsport Ltd, Unit 15, Red Lion Business Park, Red Lion Road, Surbiton,
Surrey. KT6 7QD. Tel: 0208 391 0121.
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