Well when Dave Kern starts something he is most likely going to finish it. I mean seriously. His wife Allison recently recounted the time that the motor blew during a race, fire was shooting out of the hood, over the car in large balls of glowing heat and she had to tell him that it was over, they had to pull over. Well, this same determination goes for fabrication of the ultimate race car too.
This years car features a complete composite body, about half of which is being fabricated by Dave with a bit of help from me. The other half are commercially available parts. The new car will feature larger, stickier tires, more elaborate aerodynamics and a full flat bottom to also aid in the aero. Wow, it is a ton of work and wow I wish I had more time to help him out because I feel bad that he is going at most of this alone!
Check out some photos from the build so far.
My composites professor from Metro has decided to tackle the front aero. With a brand new splitter that should actually weigh about 1/3rd of the weight of the current splitter… well this thing should be mean
Check back for more and check in with RaceKern for even more details on the build.
I was just minding my own business at work on Friday when I get a text message. “Find a truck and Trailer and the BMW is yours to race on Saturday.” I consider myself a fairly honest person, but I’ll steal a truck and trailer for that opportunity! After some quick searches I got another message “truck and trailer are taken care of.” Holy crap, that is even better.
So off we went, we headed out to CORE unloaded and signed up. I realized I hadn’t driven the BMW in about 7 months so I figured it should be quite entertaining to see my tentative first runs.
Once on track we had a pile of fun, it was a very windy day and I was driving with Grant Hughes as a second driver in the car. Dave brought out the EVO aka the Evil (according to voice-to-text) and though we didn’t win any awards (though Grant nearly clinched the Cone Killer award) we had a blast.
The photo in this thread is pulled from this PhotoBucket stream. Once I figure out how to contact the guy I may just have to get this thing printed!
What do you get when you take a high powered EVO made to run the toughest hillclimb in the nation and put its rally shoes back on? Well, you basically get a low level aircraft!
After a bit of a rough ride at Pikes peak this year the car is back in action and ready for another local hill climb. Monarch is part of the CHCA series, in fact it is the last race of the series. The Kerns currently hold the record on the hill when they ran previously in the EVO with almost 200 less horsepower than it has currently. After fixing damage, replacing parts and basically converting it back to a rally car we took the car out to CORE to test it out.
The EVO has so much power that all four wheels spin in nearly every gear on the dirt. It is a bit of an incredible thing. In addition it goes so much faster than the BMW that when you are going along the same course you spend close to double the time simply off the ground. There were several times when I thought: “Hmm, I sure hope we can land, regain traction and make that corner right there.” The funny thing is that the Ohlin suspension is so smooth compared to the BMW that even though you can tell you are going faster, the visual inputs are coming at you quicker, but it feels so smooth that you feel as though you are either going the same speed or going slower than the BMW.
After a solid run at CORE we packed it up and headed home. No need to run it all day but we had a good solid test and it was a bit humbling to see Dave say with what appeared to be genuine surprise. “Wow, after testing with the BMW all summer, the EVO is FAST!”
If you looked up the word ‘determined’ in the dictionary, it says “see racekern.com.” The Kerns have had some of the toughest years at Pikes Peak and each year they come out of it wit a smile on their face and a lesson learned. Some of those lessons I don’t think they could have ever avoided so it is amazing how positive and driven they can remain!
This year’s lesson? Dirt may be scary at times, but asphalt has many faces to. The thing about dirt is that you are relying on a surface that has minimal grip, so you are driving in such a way that you are constantly compensating for that lack of grip. On asphalt you are using all the grip that you can get out of the road. So if that grip goes away, you have a much tougher time. This year the Kerns found a part of the course that dust, gravel, something was blown onto the road and braking grip was eliminated! Stephan Verdier found the same place, but his experience was even more catastrophic! So ride along with the Kerns as they take you up the mountain. Keep your eyes peeled for their incidents and for the pieces that decide not to make it all the way to the summit with them!
Take a moment and read the Kern’s recap on the week at Pikes Peak on RaceKern.com
Every year I go up to Pikes Peak for the hill climb and every year the adventure is a bit different. I have worn many hats on the mountain including Photographer, writer, video guy and even tour guide. This year was a bit different. My roll this year was a bit more involved with the teams and it really gave me a good look at what they have to go through to make it to the summit.
Now let me clarify, the teams that I have been spending more time with are all small budget teams. These are guys and girls that don’t have the big dollar budgets and the ones that are sometimes the most impressive on the mountain with the least amount of fanfare. This year I spend the most time with the Kerns.
Dave and Allison are a great duo of Husband and Wife, Driver and Co-Driver. They have two race cars and I am pretty familiar with nearly all the nuts and bolts on both of them now. Their BMW Compact race car you can see more info on the build on my site and the EVO is their hill climb car for Pikes Peak. They seem to always find just enough support to be able to pull off another hill climb and they don’t show up with junk. The EVO is over 600 hp at the wheels, it is very well thought out with weight reduction measures taken at any place that they implement them. It is a rocketship with tires in my opinion and in the capable hands of the dynamic duo, it is a force to be reckoned with.
The other teams, who’s cars I don’t work on, but who I spend time with instead are the teams of Spencer Steele and Jimmy Olson. I met both of these guys through Ice Racing in Georgetown and these guys, well they are best friends and some of the fastest guys on the mountain. Their budgets are reflected in their vehicles as well. Spencer has a philosophy that you don’t paint a car till you can find out what color duct tape you can buy and Jimmy, well, he’s actually driving a car for a different owner named Butch. Both of them have a collection of used tires that they have collected from other teams, they have motors that they built themselves and every part of the work on the car they have a hand in. None of these teams tuck their driver in to get a good nights sleep then go to finish work on the car, the driver is the main part of the team and is integral in making the car go both on the course and in the pits.
In the weeks leading up to PPIHC these teams were working on cars. The kerns were driving to Chicago to get a new AMS power package put into their car. Spencer was building a motor and Jimmy, well he was trying to get his own car running for the event when catastrophe struck and he ended up running in Butch’s car. Exhaustion leading up to the event is a regular thing for these guys and with minimal support a lot of this is just out of pocket expenses too. On Tuesday night, the night before practice, we were under the Kerns EVO readying the car for the next day on the mountain and though the car was mostly ready, the final touches took till nearly 11pm to get through. With a wakeup call at 2:30, that makes for a short night!
On the mountain the first day, the Kerns were battling an under steer issue. With new suspension that they hadn’t been able to test due to rained out track days, they were experimenting on the mountain with the new suspension setup and it was pushing like crazy. Spencer and Jimmy were experimenting too, but they were working with different tires. With all the new pavement on the mountain the tires that they have used in the past, the Pikes Peak Specials, seemed to be too dirt oriented and not quite as pavement friendly, so they were playing with different front tires, different rear tires and run after run you would see different things being tested.
After practice the Kerns headed off to PPIR to continue testing and tuning. The suspension needed to be changed, tire pressures needed to be dialed in and the handling needed to be corrected. After hours at the track only a minimal improvement was felt. It was clear that they were missing something, but there was still time. With that being said, I as able to ride in the car for the first time at the end of the day and experienced a vehicle that has some intense amount of power. 0-60 seems like a silly measurement in this car as you feel that you could just barely stand to drive this thing 60 when it has so much more power to go. Maybe 0-100 or 0-150 even is more appropriate!
Practice day two came about and the same tweaks were being made. The kerns were working with suspension and at the same time AMS tuner Mitch was dialing in the tune on their motor. Jimmy and Spencer were clearly testing tires on each section to see what they could figure out would be faster and I was on the side of the mountain taking video of all of them. In case you don’t remember, last year we ran cameras on most of these cars and this year we stepped that effort up quite a bit. Cameras on the cars and a lot of video from the side of the mountain as well. This is a huge undertaking so check back in a week or so and I will have our final edit up for you to check out.
After practice the kerns headed out to PPIR again, this time they had an infield spot to work on the car. Federal Tires rep Taz Yeh came out to lend a hand and his help was fantastic. His knowledge of the tires and the suspension worked out well and they were able to dial in the suspension and tire pressures to really meet Dave’s driving needs. At the end of the day we laid down a final run on the track. Fully drifting most of the turns in 3rd gear with predictable handing in an AWD car… what an impressive feeling!
Practice day three was qualifying day. This was also the only day on dirt and the dirt was LOOSE. Yeah, The kerns headed up on their newly dialed suspension and they were looking quick. 5:09 was their qualifying time which bettered their previous best qualifying time on the mountain! This was good for second qualifying position however by 4 seconds and they were sure that they could find the extra seconds on the mountain. Jimmy and Spencer were battling out in their own class. Jimmy put down a 5:00 and Spencer a 5:07. With these two guys though that difference in time was going to be cut down… You can just feel the competitive nature between these two best friends! After practice everyone was off to Fan Fest.
Saturday the teams were dialing in, changing oil and just finalizing the prep for race day. Spencer and Jimmy were aligning their cars when I stopped by and as you can imagine it was unique. Big teams, they use tire alignment machines, lasers and other goodies. Jimmy and Spencer? They have a tape measure, a retractable dog leash 4 beer cans and a stick of aluminum. Now keep in mind they have this down to a science. They use two Coors cans on the back of the alignment bar and one Coors and one Bud can on the front… since the Bud can is shorter.
Race day came and the crowds were just huge. It is great to see people recognizing the majestic nature of this mountain and this race. I was asleep at Devils Playground and when I woke up there were probably 500 cars around me. It is a great sight to see! The weather was warm but a bit windy. Overall it was a perfect day for a race and clearly a great day for the unlimited class. Monster set a new record of 9:51, Rhys at 10:09 showed that his car was really capable on the mountain in only two years of running that car and Jean Phillipe had a very impressive appearance at 10:17 which is amazing for the first year on the mountain at all!
The Kerns were poised to break their own record. They headed up the mountain and as they did I turned my radio off. I didn’t want any of that audio on my video. So I waited. They passed by and when I saw their car my heart dropped. Something’s wrong. I turned the radio back on and found that they had crashed at ragged edge and later found out that they crashed, lost a headlight, lost a side skirt, tore a hole in their front suspension and tore the tire on their rear wheel. By the time they got to Cog Cut the were running on a rim and when they got to the top at 12:12 they found that they had just placed 4th in their class… 15 seconds down from the leader while running a flat for the last 5-6 miles of the race. Pretty amazing if you ask me, especially when the race is 12.42 miles long!
Jimmy and Spencer were battling it out as well. Both passed by at a crazy amount of speed and in the end they were separated by 1 second. 1 SECOND! It is incredible. Spencer took the win; Jimmy took second with Spencer’s time being 10:42. Now, here is a little detail for you. This is what impresses me the most. Spencer’s time of 10:42 was set in a car running used tires, a home made motor and duct tape nose cone. This is a homemade project with nearly no support. Spencer’s time was good for 4th fastest overall time on the mountain. This is up with cars that have hundreds of thousands of dollars wrapped up in them. Cars that show up with a crew of mechanics and specialists. Both his time and Jimmy’s time is just incredible to me when you look at the budgets involved. This is what makes Pikes Peak most impressive to me I love that a team with a car built in their garage can show up and challenge the biggest budget factory teams. I think it is an incredible race when money doesn’t dominate and experience skill can win. This really makes this race awesome to me and I am pretty fortunate to have the ability to spend time with these guys and experience the race through their eyes!
I will have a video up from all of these cars and more very soon, in the mean time, check out some quick teasers…
Three days of practice are done. Qualifying has happened and the results are online. The Kerns have been dialing in the vehicle all week. With a major change in suspension this year in response to the added tarmac the testing to dial in the suspensions performance is critical. We were finally able to get it dialed in to Dave’s needs on Thursday night.
This year Dave and Allison have been supported by AMS again for his engine setup, tuning etc. They have also been picked up by Federal Tires. One of the nice things about both of these sponsors is that they are here, they are hands on and they are bringing their own setup experience. So out at PPIR this week while testing they have been hands on, talking about suspension setups, tire pressures engine setup and more. It has been a very interesting experience and I can’t imagine that we would have gotten the setup to dave’s liking as quickly without them.
As we were heading out Dave Carapetyan’s crew rolled up with his newly built Unlimited car. So new in fact that it didn’t get to practice all week.
They were in for a late night and said they were hoping to be at practice on Friday however a blown head gasket held them back from that goal.
We’ve been shooting video all week as well, as you may remember from last year, we are doing a similar project again this year. Spencer Steel, Jimmy Olson, Savannah Rickli and Dave & Allison Kern are all participating and we may even have some video from a motorcyclist, Darryl Lujan. So far I have a ton of video.. I mean seriously, I can’t get through it all just yet, but I can show you a bit of a Teaser… So check this out.
I don’t know why I forget this stuff, but I am remembering how much work making a mold is… Yeah. It is one of those things that I remember when I really think about it, but when I haven’t done it for a while I convince myself that it will just take a few hours.
If you haven’t seen part one of this build check it out here. This time I have been going layer after layer, working my way up and trying to get a nice smooth final product. There have been some tricky parts like the airbag area and the vent holes. In addition the portion that I have made with foam is a bit tricky as well, occasionally when you get beyond the bondo layer you find out what happened very quickly when you hit the soft foam! I reached a point where I needed a much better visual indicator of what was going on. So I had to put a coat of glossy paint on in order to see the lines better than I could with the flat primer. So I chose a red paint and painted it up. It gave away some issues immediately. There were some sanding marks that were a bit deeper than anticipated, some waves that I needed to sort out and basically it just did exactly what it needed to do.
So I did a full wet sand on the part and really smoothed it out. some spots got all the way back to bondo again through the paint layer and the primer layer. Once I got it all smoothed out another layer of glossy red and WOW! what a difference! It looks very good right now. There are a few little imperfections, they are all pits and will actually be easier to fix in the mold itself so I am going to leave them and sand them out of the final mold.
After the mold was fully prepped we took aluminum tape to create the rest of the part. Basically the part needs draft, so using the tape is much faster and easier to shape for portions of the mold that we don’t care about. Plus it doesn’t really stick to the fiberglass, so that helps as well.
I believe that there will be two more parts to this project, one more for the mold making and one more part for the final part that we pull off the mold. Check back soon!
The Kern’s BMW is finally running. we rocked, we rolled and Dave just straight up deprived himself of sleep and rest, but in the end: that car rocks. Yes, it is running. we finished up saturday, did a big donut in the parking lot at around 9 pm and then headed out to CORE for some testing at 10:30 the next day.
First impression… EVERYTHING WORKS! it is incredible how many little things you need to think about when you do this type of thing, but everything works! It is kinda a miracle. The car was a blast and Dave gave me a ride in it to show me what all the sleep deprivation, bloody knuckles and just general tinkering is all about. Man that is fun.
The course is rough, it is narrow and it is pretty quick. I think we topped out 5th gear in the straightish parts and jumps, tight corners and “other” were regular occurrences. It makes me want to get my hands on a car that I can play out there with…
No post is complete with out video right.. well check out some in car action!
I’ve been helping Dave Kern build his BMW rally car whenever I have free time. Unfortunately that isn’t that frequent! It has been teaching me a lot about cars and letting me do one of the things that I enjoy the most, figuring out solutions to problems!
Dave has about 16 months into this car, I have maybe a few weeks, so I can’t take a whole lot of credit, but I was down there the other night and we got some of the “you may actually drive this soon” parts put on. Brakes are bled, the engine is all ready, pedals are in, skid plate mounts are in. It is actually looking like we may run this and stretch its legs this Sunday!
A quick note about Dave. Man can that guy drive. It is pretty incredible really. You don’t really have a solid appreciation for what a good driver can do until you are riding along and seeing all the things they can do with a car. Last year he drove my car at Georgetown and I watched as my car did things that I didn’t know it was capable of. I am pretty sure that even Subaru may have been baffled. This year I rode in my car again with him at the wheel at BWDS and again, wow. How does it do that! However one of the most awesome experiences was in Mitch Williams rally car. Dave threw that thing around and at one point said “yeah, that is about as far as I would want to push someone elses car.” I was thinking “well that is about 45% more than I would want to push my own car! Allison, his wife and co-driver is brave enough to ride with him and incredibly skilled at keeping him on track. I suspect we will see her behind the wheel of the Bimmer soon! Check out their website in my links, you’ll be following along with their adventures soon enough.
When the pedals are in, the steering wheel was installed and we could sit in the drivers seat. Well your imagination puts a track in front of you. Your peripheral blocks out the shop walls and you create the sense of speed and suddenly you realize that you are making the engine sounds you imagine will emerge from the hood. Yes, we both did this, but Dave quickly remembered…. TURN THE KEY!
I’ve been living vicariously through some of my friends by helping them with their race cars. Mostly I’d say it has been Dave and Allison Kern. Originally I had helped them with some work on their Pikes Peak Hill Climb Evo. I did a bunch of work on their aero package, but also ended up welding some parts as well as installing and fitting body parts as well. It is fun to get to work on this stuff. There is a lot of problem solving and a lot of building, creating and working with your hands. Currently they are working on the creation of a BMW rally car.
The BMW will be used as a 2wd Rally car. It is cheaper to run and compete in and with a privateer budget that is good news. It is also going to provide the opportunity to run in Max Attack which is a 2wd specific rally event that will give them good competition in an affordable package. If all that wasn’t enough the BMW will be set up so the drivers seat is able to accommodate a shorter driver or a taller one…so Allison now has the ability to drive!
The car has been caged by SCR Performance but Dave is taking on the majority of the rest of the work. The beginning steps (beyond all the research that he has into figuring out the parts for the car) is the underbody. The BMW isn’t exactly designed for Rally, so you have a couple options. Paint the car and replace the chassis when it gets wrecked or try to protect the chassis. The plan for this car was to protect the chassis with Kevlar and Macropoxy. Macropoxy is a paint that is a good barrier against rust and light impact. Kevlar, well that takes the bigger dings and dents well. The EVO Works well with the Kevlar under body, but it is separating a bit in places, so this time we tried a few different tricks to try to keep the body and the kevlar together.
The Kevlar now has epoxy that has been seeped into all the welded seams so it hopefully gets more adheason, also we put chunks of Kevlar into some of the gaps between seem welds so those will hopefully give the kevlar even more places to adhere.
It is a messy process, so we only have a few photos of this part. This is what the end result looks like. Almost time to flip the car over and start putting parts on it!
I’ll be helping them out whenever I can, so keep an eye back and I’ll post up some progress as we go. In the mean time you can check them out on Facebook