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Discussion Starter #41
So we're making progress! I was hoping to have protos by now, but we're making some really good tweaks to the designs.

Should have proto sets in hand in about 5 more weeks. Production will be available over the holidays/january. In time for the 2016 driving season.

Attached a few pics below: We have a very beefy semi-helical design to add strength and keep it running quiet.

We have aggressive fillets on all the gears on the input shaft AND we're probably going to do the input shaft in 300M vs 4340 for everything else. Both materials are superior to the 9310 used by the OEM.

1st -4th gears are beefier and wider where possible.
 

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:drool:

After I get my car built...I know what I will be saving for next. :wallbang:
 

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Discussion Starter #46
We don't have the pricing locked down yet. We need to get the protos done and make sure were happy with the fit, function etc. to lock that down. The price will be a good value for what we're putting together. Class-A + materials, design, and heat-treat throughout. I have zero desire to be the "low-cost leader" with chinese crap. We've seen one popular gear set in our transmission shop alot lately with exploded gears.

The ratios are probably good, but until we cut and fit them, they could move around. The MPH I listed at the beginning of this thread is representative of those ratios. There will be alot of flexibility since the stock ring + our Ring and Pinion along with taller 6th gear option for cruise. We're going to setup our Ultimate Street Car with our Ring & Pinion + the taller 6th for cruise. I'll post the ratios once they are locked down too!

Thanks guys!
 

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Discussion Starter #49
On the Torque(Torque is the killer, not HP) side, its got a ton of of variables. Stickiness of the tires, Launch Load, Engine Torque etc. etc. We've seen failures in the Pinion Gear from Launching, 2nd and 3rd from repeated over torque, and repeated synchro death.

I am really fortunate that not only do we have a proven high performance/racing gear and shaft partner, but we also have 3 different material & engineering experts consulting!

- Combined 80+ years in materials science, specifically high strength steel design and use in motorsport, aerospace, and OEM gear, shaft, and axle applications.

We're upgrading to improve all these areas:

Most important is design:
-Wider 1st, 3rd, 4th to add strength
-Improved fillets in key areas to reduce stress risers
-Bigger, thicker gear roots to vastly strengthen teeth
-Lower Helical angle to improve strength.
-Closer ratios to reduce the work on the synchros for longer life

-Better material and heat-treatment.

Stock uses a softer, case hardened steel. They do this because it is easy and cheap to machine and the case hardening gives about 0.040" of hard outer layer for wear and tear.
We'll be using 4340 THROUGH-Hardened steel for everything but the input shaft. This provides a far tougher, more flexible part:

The input shaft will be 300M. 300M is "super 4340" and damn-expensive. It has even higher toughness, ductility, and greater surface hardness and crack resistance. This part will also be cryoed as standard.

Above and beyond this, for even more extreme duty, we have a proper Aerospace grade shot-peen partner(they shot-peen Apache rotors(GunPilot giving you the shout-out!)) AND the correct SAE spec for media and intensity to add significant compressive pre-stress for even higher durability. Not some guy blasting parts randomly in a booth in his garage. Each lot has a pair of SAE standard test strips to show the peening intensity. This will be an option since it is not cheap.
 

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Discussion Starter #50 (Edited)
Really this solution fits a specific target. If you are looking for 750HP drag car with Mickey Thompson slicks, it probably isn't for you.

This is for folks with a modified Elise or Exige with TVS400 type power that wants to:

1. Have daily driver convenience of the stock 6 speed synchro box.
2. Lower noise vs. straight cut gears
3. Better ratios for the power i.e. taller 1st and 2nd for stoplight duels.
4. Better ratios for the track i.e. closer throughout to keep it in the powerband
5. Reduced synchro wear from tighter ratios.
6. Option for a tall cruise 6th to comfortably get you to and from work or fun.
7. Same weight and packaging as standard box.
8. "No compromises Race-Ready" design, heat treat, and materials for good service life with higher than stock power.
 

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I am planning a engine and trans upgrade. it would great if you could give a ballpark range for the 1 to 4 gears. we will not hold you to the price
 

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Discussion Starter #53
I am planning a engine and trans upgrade. it would great if you could give a ballpark range for the 1 to 4 gears. we will not hold you to the price
I'll see what I can put together next week. Remember that 1 - 4 will be 6 gears + input shaft. 1 & 2 drive are built into the input shaft. Then you have 1 & 2 driven + 3 & 4 drive and driven gears.

Ring and pinion will be a separate option if you like.
 

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Really this solution fits a specific target. If you are looking for 750HP drag car with Mickey Thompson slicks, it probably isn't for you.

This is for folks with a modified Elise or Exige with TVS400 type power that wants to:

1. Have daily driver convenience of the stock 6 speed synchro box.
2. Lower noise vs. straight cut gears
3. Better ratios for the power i.e. taller 1st and 2nd for stoplight duels.
4. Better ratios for the track i.e. closer throughout to keep it in the powerband
5. Reduced synchro wear from tighter ratios.
6. Option for a tall cruise 6th to comfortably get you to and from work or fun.
7. Same weight and packaging as standard box.
8. "No compromises Race-Ready" design, heat treat, and materials for good service life with higher than stock power.
Take my money! :D
 

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Dumb question....but would mpg be impacted that much? This is definitely something I want to add after going Rev!
 

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Dumb question....but would mpg be impacted that much? This is definitely something I want to add after going Rev!
Adding the C60 6th gear from the Celica will boost your highway mileage and save your ears by dropping cruising RPMs 11%. This is one of the options listed earlier in the thread. I have it in my car (not a BWR box), and it's great!

As far as city mpg goes, it depends how much second cam your city driving involves. :UK:
 

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Discussion Starter #57
AFM is correct. The mileage generally won't change much except based on highway RPM cruise. The taller 6th is great. Out here in the west standard highway speed is 80mph, so the stock 6th is a bit of a buzz bomb. The taller 6th fixes that. With standard lotus we picked up about 2mpg highway with the taller gear.
 

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Discussion Starter #59
Hey mate is this going to come as a kit or as a fully assembled GB? Only reason I ask is I'm from NZ and shipping would be a nightmare on a full GB. Thanks


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Good Question! Our place is to offer both. We'll have fully-assembled gearboxes available with core exchange or have the parts available.

My guess is that many folks domestically will go the core route as there are several pitfalls in disassembly and assembly for the novice, not unlike building and engine. It is easy to break a few gears in disassembly without the right tools etc.
 
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