CMP Test Day

Note:  This event took place on 30 July 2015, just getting caught back up with posts.

Setup in the shade at CMPMy last test day at Carolina Motorsports Park ended prematurely when my radiator popped off its mount and the belt cut into the coolant expansion tank.  With the car back home I pulled the plugs to check the compression since it saw temperature spikes over 250F.  Fortunately the numbers came back good, actually matching the numbers I had taken when I first installed the engine.

I put the car back together, this time with a new CSF OEM+ radiator and a cooler 80C thermostat while ditching the stock fan, and headed back to CMP to get some testing in.  I knew the car needed some chassis tuning after its first race post-crash.

Adjusting the front barIt was a low turn out at the track, so we were able to double up on track time.  That’s 8 full 30 minute sessions.  That’s a lot of driving in a single day, so I cut a few sessions short and skipped the last one.  What I did discover was that I needed a little more rear end grip.  The week prior I had done some ride height adjustments and corner balanced the car at a friend’s house.  The first couple sessions were a mess, I either spun or got into some serious tail out action.

I brought the car in and decided to stiffen the front bar one notch.  This had an immediate positive impact, the car was much more neutral, at least as much as I could get it on CMP’s slick surface.  Either way it felt much better and gave me more confidence going into my upcoming NASA race at Road Atlanta.

As for the engine temps; the car ran much cooler.  I was seeing a high temp of around 202F, albeit in completely clean air.  Looks like removing the stock fan and shroud allowed for better flow through the radiator.  I also had done a little work with foam rubber insulation to force air through the radiator rather than around it.

 

Spec E46 Test Day Ends Early @ CMP

Note: This event originally occurred on 12 July 2015, I’m a bit behind in my posts.

Following my first full race weekend, which was a mad dash to ready the car, I knew I had a few bugs to work out.  Chief among those issues was a persistently warm running engine.  Of course this was in the heat of the South Carolina summertime, but I wanted to get my temps a little lower.

To that end; I installed a larger CSF all aluminum radiator specifically for the E46 non-M chassis.  Unfortunately the mounting points weren’t ideally designed to interface with the factory plastic mounts.  I did my best to modify the mounts to work, installed it, and off I went to Carolina Motorsports Park for a day of testing.

Spec E46 Testing at CMP

I went out on my first lap and found that the temps were much lower.  Prior to the new radiator I was averaging ~212-215F in the heat of the day.  Now I was sitting at around 202F, much more reasonable.  I pushed on harder for the next couple laps, besting my previous times by more that 2 seconds.  Then on the third or so lap I got a warning light briefly for engine temps.  It went away as I looked down at the dash to decipher what the problem was.  Then a few seconds later it reappeared.  By now I was paying closer attention to the numbers, and I watched as the water temp spiked to over 250F then back down.

I immediately let off the throttle, short shifted, and brought it in to the paddock as quickly as possible using as little engine as possible, coasting the last hundred feet or so with the engine off.  Hopping out I could see steam rising from the engine compartment.  A peek under the car showed hot water dripping to the ground.  This certainly wasn’t any good.  Popping the hood confirmed my concerns about the mounting of the CSF radiator.  It had slipped from its mounts and shifted rearward where the expansion tank made contact with the serpentine belt.   The belt made quick work of the plastic tank, sawing right through it.

My day had come to an early end with a destroyed expansion tank, a radiator that wouldn’t sit securely, and possible engine damage.  Later on, after everything had cooled, I also discovered that high temps had destroyed the expansion tank cap.  The lower portion that retains the sealing o-ring was completely missing.

Damaged Expansion Tank Belt Cutting Expansion Tank

The good news: CSF was quick to help rectify the situation.  They sent me one of their OEM+ radiators, covered the cost of the expansion tank, and promised to redesign their all-aluminum radiator.  Hopefully they get it corrected soon, because other than the mounting problems, it’s a solid piece.

And finally a short video of my one hot lap before the radiator mounting failed:

httpvh://www.youtube.com/watch?v=-DuvY_UuF9I

Spec E46 Race @ Carolina Motorsports Park

Note: This Event originally took place on 27-28 June 2015, sorry for the delay in posting.

Having finished the requirements for my provisional racing license, I was looking forward to the next opportunity to race my Spec E46.  The upcoming NASA-SE event at Carolina Motorsports Park (CMP) looked very promising, with a possibility of five other SE46’s in attendance.  One slight hiccup; my car was still in pieces.  Several delays in parts shipping meant I was way behind my anticipated competition date.

Rob's 609 Spec E46I had already committed to this race, having already cancelled the previous Road Atlanta event due to the crash, and I really didn’t want to miss another opportunity to get some much needed track time.  The week leading up to the event became a mad thrash.  I was working until the wee hours of the morning right up to the day before the race.  The good news: CMP is only an hour away from home, so at least the few hours of sleep I did get were in my own bed.

I also needed an annual tech inspection the morning of the event, so everything had to be just right.  I escaped with a few minor discrepancies which were easily corrected and was able to make the race.  I had barely got the car off the alignment rack the night before, so there was zero time to shake down the car, much less tune the chassis.  I’d run what I brung as the saying goes.

My setup in the grass Fellow SE46s in the paddock

I missed the first practice, fiddling with a few last minute things, but was able to go out in one of the HPDE sessions to get a feel.  I knew the track was slick from my previous test day, but having an untested car made it much more of a challenge.  My goal was to just keep the car on track and avoid any contact, speed was way down my list of things I was worrying with.

View of the Spec E46 groupI qualified at the back of the SE46s, as expected given the all-star veteran competition I was up against.  No big deal, I was here to learn.  We, as a class, decided to start at the back of the Thunder run group in our own separate start rather than gridding on pure time.  The first race started off cleanly, but I was out of it both mentally and physically.  The lack of sleep had caught up with me big time, and I couldn’t maintain my concentration and felt like garbage, my times were reflecting my condition.

I continued to press on, just looking to finish when a red warning light illuminated on my AiM MXL digital dash, water temps.  I was at 230F and it looked as though it would keep climbing.  I had pressed my luck enough already, so I pulled off that lap and putted back to the paddock area.  I couldn’t find any obvious issues with the cooling system, all signs pointed to trapped air bubbles.  This is the price you pay when rushing to get a car ready at the last minute.

Sandro's Spec E46I decided to pack up for the day, let the car sit and cool overnight and get some rest.  Another SE46 driver had already had worse luck when one of his rear shock mounts failed, resulting in a destroyed MCS shock.  I left early to get caught back up on sleep and hopefully have better luck on Sunday.

The next day I jacked up the front of the car and bled the cooling system thoroughly.  It looked like my suspicions were correct and the engine had some significant amount of air trapped in it.  Feeling recharged from a long night of sleep I headed back on track, this time in a much better frame of mind.  The car still wasn’t working as well as I had hoped, oversteering terribly on exit and pushing on entry, but it would have to do.

Saturday's Race(Note how I was still missing the trim under the headlights and decals from the new fender)

Again I started at the back of the SE46 pack, where we started as group behind the rest of the Thunder field.  This time I felt a little more confident making passes and tried my best to hang on to the back of the SE46 in front of me.  I certainly wasn’t pushing for overtakes, rather waiting for the safest opportunity to get by slower traffic.  Towards the end of the race I could see I was closing back up to the next SE46 up the road, but every time I tried to push, the car would just lose traction on exit.  I was at opposite lock over and over, watching the Mustang and other SE46 in front grow the gap.

My Spec E46 at CMP

Despite the headaches and lack of a good setup, I still had a blast driving with other SE46s and finally getting a chance to mix it up in traffic in an actual race.  This was, after all, the first race where I got beyond the first lap.  It was great to meet and hangout with other racers in the paddock, gleaning knowledge wherever I could.

Finally a little video from the weekend.  Due to my zombie-like state on Saturday, I neglected to bring the memory card for the camera.  I made sure to get it for the Sunday race.  Here’s the race in its entirety:

httpvh://www.youtube.com/watch?v=GFrz5KTHV20

NASA Comp School @ Road Atlanta

Note: This event originally took  place on 5 June 2015.  I’m a bit behind in my updates.

When I built the Spec E46, I intended to run it both in the BMW CCA Club Racing series and NASA racing, where the majority of other SE46s in my region were running.  I had completed the BMW CCA race school back in January of 2014 at Texas World Speedway, which allowed me to run my first race at Barber with the CCA.  Unfortunately that didn’t turn out so well and the car was laid up for serious repairs.

I had hoped that the NASA South East region would accept my BMW Club Racing license and allow me to run without attending their Competition School.  Unfortunately they were not willing to do so for a Rookie license.  I’m sure if I had multiple races under my belt it would have been fine.  Since that wasn’t the case, I needed to get registered for their next available school.  My luck was running even more thin when the next upcoming school was coming up in a hurry and I had no car ready to go.  Unlike the BMW CCA school, which allows you to use your street car, NASA requires a fully prepped race car with current annual tech inspection.  Waiting until my car was ready would have meant missing out on a good chunk of the season and having to attend the school at ViR with Mid Atlantic, a place I had never run.

I thought my luck had changed when a NASA-SE regular offered up his Scion FR-S for rent on the day of the Comp School.  We agreed on a fair price, I signed up for the school, and off I went to Road Atlanta.  It felt rather odd heading to the track with nothing in tow and only my driver gear in the truck.  My father and I arrived late Thursday night to meet with the gentleman renting his car and get a test fit.  I had already warned him that I was 6’2″, with much of my height in the torso, but he was confident that with the seat in the lowest position I would fit.  Bad luck struck again; there was no way I would safely fit.  My head was touching the roof cross bar, even scrunching down.  It looked like I would be heading home sans certificate.

Before we gave up, I started making the rounds of the paddock, looking for anyone who might have a ride available.  All the Spec Miatas were already claimed, not that it would be any easier of a fit.  The regional director even tried to get me a Thunder Roadster ride, though that didn’t pan out (probably best for my own well being!)  Then I remembered that a fellow CCA racer had previously offered up his K-Prepared E30 for rent.  I got on the phone and tried to work out the logistics of getting the car from nearby Atlanta.  Then I remembered; the car had to have a NASA annual tech sticker.  Out of luck once more.

By this time the sun was dropping and folks were leaving the track to rest for the following race day.  As a last ditch effort I text messaged a friend who was from the local area, just to see if he had any leads.  He told me to standby while he checked on something.  Perhaps this would be the solution.  As it turns out, he was going to rent a Spec E30 the same weekend and planned to run it in practice on Friday.  He checked with the owner of the car and came back to me, offering to give up his test day so I could complete the comp school.  My luck had finally turned around.

Spec E30 Tic Tac

Later on Thursday I tracked down the rental SE30’s owner and we picked up the car from a nearby shop.  Even better news was that I fit just fine in the car, the seat being a larger size and also on sliders.  We parked the car with the rest of the SE30’s and went to the hotel, finally able to relax and know that I had a chance to get this school over with.

The next morning started with a sprint which didn’t stop until the day was complete.  See NASA essentially squeezes a two day comp school course into one day.  So there is very little downtime between sessions and class.  You are in the car, then directly to class, then right back out on track.  I was even driving the car directly to the classroom, so that I could hop out and in.  Having my father there as crew chief was a life saver.  While I was in class, he was topping off the fuel, loosening the belts, and torquing the wheels.

The school itself went by without much drama.  NASA does the school in conjunction with test n’ tune sessions, which provides extra traffic to negotiate, mostly much faster traffic at that.  To me it felt as though the major focal point was ensuring drivers were comfortable in close proximity to other cars and obeyed flags.  There was little discussion of race craft, as had been a key point during the CCA race school.  Much of that can be chalked up to the school being on a accelerated timeline, giving very little time to really discuss the nuances of driving in a race.

Just like the CCA school, the day involved side-by-side drills, swapping places in corners, and ended with a mock race.  Our first mock race was an inverted field and standing start.  Apparently I was the fastest SE30, so I had the other E30s and SMs in front of me, with a gaggle of Mustangs, Corvettes, and a really fast GT-R behind me.  I got a clean start, passing everyone in front by turn one and led up to T3, where a Corvette whizzed by.  A full course yellow was thrown about midway though, and we got to practice a restart.

A “Fun Race” was set to conclude the day.  I initially hadn’t planned to participate, as I was going to save tires/fuel and head back home that evening.  That plan was squashed when I was informed the race was not optional and was a requirement for finishing the comp school.  It was an hour long race, so I just planned to complete 50% of the leader’s laps and call it good.  The start/finish stand marshal was kind enough to give a midway signal, and I pulled in unscathed and finished with the school.

SE30 at Road Atlanta

I had never even driven a street E30, so I wasn’t sure what to expect.  My M Coupe shares its rear suspension with an E30, so I was a bit worried it’d handle in the same manner (ie short wheelbase + lots of power + semi-trailing arms = never lift), but the SE30 was much more benign.  The lack of power, tall gearing, and sufficient grip meant the car was very forgiving.  I was nowhere close to pushing the limits with it (I certainly didn’t want to buy it) but still had a blast.  The lack of power steering and soft suspension made it seem lethargic in comparison to my SE46, but I can still see why they are a fun class to race in.

All in all it was an enjoyable day, especially getting to drive something new and very different.

First SpecE46 Race: Barber Motorsports Park

The time had finally come to put the Spec E46 race car to the test in wheel to wheel competition.  I signed up for the May 2015 BMW CCA Club Racing event at Barber Motorsports Park in Leeds, AL.  I had never driven the track, so there would certainly be a lot to take in.SpecE46 at Barber

If you haven’t been to Barber, you should really make a trip to visit it.  It has to be the nicest race tracks in North America, with finely landscaped grounds, excellent facilities, and perhaps the greatest motorsports museums for the motorcycle and Lotus car enthusiast.

Two SpecE46 at Barber

This event was put on by the BMW Car Club of America, so there were multiple run groups of DE in addition to the race sessions.  The schedule called for three races, two on Saturday and one on Sunday.  Two other SE46s were in attendance, so at least I would have some company in the class.  The majority of the cars were I-prepared, with a smaller mix of Modified, SE36, and KP cars.

Getting in the Spec E46

The car ran well during practice and qualifying, though I really didn’t have a good grasp of the track or the handling of the car.  I had a few mental mistakes at various points, just not remembering where the track was going.  Though it’s only 2.38 miles, the course has 15 turns, with a great variety to make things interesting.

Saturday Qualifying
httpvh://www.youtube.com/watch?v=oaxRQwBPFL4

I only ran three laps in qualifying.  I had no idea what a good time was, or even really how to operate the lap timer on my MXL, so I figured no point in running more time off the tires.  My time was a good bit off Damion Moses’, but enough to qualify second in class and 14/24 overall.  BMWCCA club events don’t group cars by class, but by outright qualifying time.  So I was sandwiched between a Super Modified and I-Prepared car.

The first race started well enough, the first few turns were without drama and I didn’t lose any positions.  Then coming onto the front straight the cars pretty much went single file and relatively slow to make it through the hairpin-like turn 5.  Right as I was about to hit the apex I caught a glimpse of something moving very quickly out of my left peripheral.  I had nothing but grass and curbing to my left, so I knew something was wrong.  It happened too fast to avoid, and I got hit hard in the front left.

The impact spun me off into the outside adjacent gravel trap.  The car was still running, so I shut it down.  After sitting for a bit, I cranked it again and attempted to get moving, but I was sunk up to the frame in gravel.  I also had steam coming out of the engine, so better to just wait.  The rest of the pack continued around for about three more laps under a full course caution (turns out another car crashed on the first lap.)  They eventually black flagged the race and I was stuck waiting on the roll-back, who was tending to the other wreck.  The car that hit me was able to be towed out and continued back to the pits under its own power.

Saturday Race Crash

(note: first perspective is from a car behind me, followed by my in-car)

httpvh://www.youtube.com/watch?v=w7vyRInVU5o

With the EMS personnel on scene, I got out to check over the damage.  The hood was buckled, the fender crushed, the bumper knocked off, both headlights destroyed, the wheel cracked in several places, and after trying to turn the steering wheel I discovered that the left tie rod was also sheered.

Eventually we got the car loaded on the roll back and back to the paddock.  There I discovered the damage was a bit worse than I initially thought.  The engine mount arms were both cracked and separated, the lower control arm was twisted, the steering rack was shattered, the airbox was cracked, the power steering pump pulley cracked, and the core support was twisted.  It was certainly nothing that could be repaired in the paddock, even if I had all the parts on hand.

SpecE46 Crash Damage Crash Damage

Thankfully I had recently installed a winch on the trailer, so getting the damaged car loaded wasn’t too difficult.  I stayed the night rather than driving back home in a bad mood and sore from the impact.  The group of racers were all very considerate and sympathetic to my situation.  And eventually the driver who hit me came over to apologize.  I have to say he was very humble and sincere, and I know that this could have happened to any of us.  I was lucky that he hit me where he did, rather then in the door, which could have been much more dangerous and damaging.  Unfortunately his car didn’t fare so well.  The whole right side was crushed in, pushing the door bars, main hoop, and rocker panel inward.

It was an unfortunate experience, made worse that it was my very first race in a recently completed car, but everyone walked away without any injuries, so I can be thankful for that.