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.
With a build of my own this year has been a bit hectic. Trying to manage my time while being committed to building and helping with the Kerns cars has been quite an undertaking. I am sure Dave would love more help, but this year sleep is a consideration…
So last year on the mountain was quite an effort by Kern Racing. They have been pushing it to the limit and as they say, if you aren’t crashing you aren’t getting better. Well, they did crash last year, then they finished 4th. Yes, that is pretty impressive considering they sat on the guardrail for 35 second, then raced 6 miles on a missing tire and a busted shock! At the end of the race last year their car looked like this.
So when they assessed the damage the realization was that the body work needed to be done and that means that there needs to be some thought into the future of the car. The race is all pavement in 2012, so the car will need to be wider, the tires will be bigger and it will need to be ready to accept them. So how about we modify the overall width of the car with a widebody kit? Well, if you are going to do that, then why not lighten the car by removing the rear doors? And if you are going to do that, why not make the entire body out of carbon fiber? Well that is what the plan boiled down too and they are in the midst of making that happen.
Dave got started on the car by ordering up a stock widebody kit and we got crackin on getting that installed. You can check out all the details of the assembly on RaceKern.com
With all the body work in progress I took a day or two to stop down and work out the details. It is a lot of work doing all the bondo work for a job like this but we got it to race car quality and we’re pretty happy.
Once it was all finished up a good waxing went down we made a mold of one side of the car. This is a big panel and we are glad to get through it without any issues.
With the mold curing still and the polyester resin still stinking up the place we rolled the car on over to the lift and started cranking away on other projects. We switched out the rear suspension, the rear brakes and installed the new front fenders. Then we cranked on the new beefy rear sway bar and looked at the front brakes only to realize we didn’t have the right wheels nearby to fit over the rotors.
So we worked on a plan for the rear wing mounting, we worked on a plan for the new front splitter and we called it a day. Tomorrow we will meet with John Wanberg. John was my professor at Metro and he is getting a bit giddy to make really cool composite projects happen. Tomorrow we are talking aero elements and primarily the splitter. I am looking forward to see what he comes up with!
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!
Well, I always find my way into various projects. It is funny, the more things you say yes too the more that you can learn. So with that in mind I set off to make a new dash for the Kern Racing Pikes Peak EVO.
For those of you not familiar with this car, I have built a few parts for the Kerns already. Last year I worked on their Aero Package and in the last few years the Kerns, piloting this car, have held the record for the Time Attack 4wd class at Pikes Peak. This team is unstoppable with the proper equipment and I am happy to be able to help them with their quest.
This year they are switching to Pikes Peak Open. This allows them a few more options in lightening the vehicle. Weight is a huge advantage in racing. Lotus has a saying “performance through light weigh” this saying just means that you don’t need as much power if you have less to move. So with the new possibilities every option needs to be considered. So Dave has been working on ideas. Remove brackets, replace windows with lexan, remove lights, remove dash…. wait. We can’t remove the dash, we need that to block reflections from the windshield. we need it to hold critical components like the speedometer and switches that we need. So instead it needs to be a composite dash of some sort. Now to give you an idea, the current dash weighs in at 38lbs. That is a lot of weight! Why does it weight that much you ask? Well, glovebox, vent plumbing, plastic bits, tabs, mounting brackets and more stuff that isn’t needed in a race car all add up pretty fast. With a carbon dash, we should be able to get that down to about 2 lbs! 36lbs of weight savings!
So to start I began with the original dash. This is to provide the form of the dash that we will end up with rather than try to duplicate it out of foam. The first steps were to mount this to a board, and begin creating the form of the underside of the dash. This dash will have a slightly different shape than the original in order to minimize material and make it very stiff and light.
I started shaping the foam and coating it with bondo in order to create a nice solid surface to create the mold from. Any factory dash is going to have texture to it and I needed to eliminate that texture. So coating it with bondo while starting to fill in the holes was pretty crucial. We are eliminating all of the vents on this dash except for the defrost vent. This one we will still need!
After the first layers of bondo a lot of sanding goes on, I kept smoothing this thing down so that the dash shape stays the same. I don’t want to lose the form of the dash while slathering it with all this bondo, so I figure work my way up slowly. Once I got to a point that I felt comfortable I started filling in gaps. Vents on the sides were the first stop.
The vent holes on the front needed to be filled next, so a piece of foam went in and bondo was applied over top. This is a bit complicated because we really want to make sure the shape holds true to the shape that the dash gives us already. The last thing I’d want is for someone to be able to identify where the vents were at one point.
Slowly I built up layers and sanded them back to get the shape correct. Over a few attempts I got this thing pretty close.
I am sure you can see that there are a lot of colors going on now. Primer grey, bondo (grey), glazing putty (white) and the actual dash (black). All these colors start taking away the visual cues of the lines that you are looking for when you are trying to make a part. So the best plan is always to coat it again every once and a while. get a good idea what it looks like in one color and start working hard at the areas that need improvement. I knew that I wasn’t ready to be done, but I really wanted to see where I needed to work the hardest so I did a quick coat of primer. Nice and heavy and this time I did black so it would give a good visual indicator.
I am sure you can see that there are some inconsistencies in this thing. It isn’t perfect by any means and it isn’t perfectly straight or anything. But this is getting very close. I have a bit more sanding to do, I have a bit more bondo to do and hopefully in the next day or two I will be able to finish up this part of the project so I can start waxing it and pulling a mold off this buck. Check back for the next part. If you have any questions, post them up! I’ll try to answer them.
Oh, notice as well, all the seams are filled, all the switch locations are filled and everything is pretty close to smooth. Details are next!
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!