KINOKUNI CAR PROJECTS
Design concepts for our new demo car!
This project will be a Suzuki Jimny JB23W body, retaining its factory separate chassis, modified to suit all the running gear from a Nissan Silvia S15!
The car will feature an easily removable body, that will flip up to better display Kinokuni products on the chassis, much like our existing display buggy. Our fluid and electrical quick release products will be used !
Stacked, Inc. in Sakai city, Osaka, will be responsible for building the platform, then to be brought to our shop in Iwade city later in the year for a fit-out of our current products and some new ones as well.
February 20132013 Feb. Throughout this project we will be using a parametic modelling software to assist with the design.
JulyHere is a test setup we have been playing with, the engine/mission is supported off the ground, while a scrap Jimny body has been placed over the top for clearance inspection.
We will be using this dummy body as a guide throughout the build.
Heres the dummy body sitting over the engine and transmission, testing the looks of some Rays TE37 in 17 inch.
Cutting the fenders out with the plasma cutter so we can test fit some wheels into our dummy body.
Would it be possible to make a race car from this frame was the question asked when it laid out in the car park.We all agreed it would be a very daunting task and so the project started.
Our base engine, with a nice set of Greddy cams, and Nismo injectors. Ready for a rebuild and refresh!
Under a large roof in the summer sun we laid out the chassis rails and made decisions on wheelbase, track and where to weld the tubes to attach the Silvia sub frames.
November 29th 2013As the winter set in we moved the chassis and parts into a container. Here the front cross member has been notched to accept the chassis rails.
The space frame pipes have been bent using an American bender which has made professional bends at a reasonable price.
June 2014We purchased a body which can be used to calculate many decisions and locations for the final car. Finding time to work on the car has become a major problem with so much more urgent work to do within the companies involved.
October 2014Our in house pro Aussie welder was busy getting the space frame millimetre perfect and adding the brackets produced by Kawai Works direct from CAD drawings to the water cutter and bender making pieces of art in steel.
October 11th 2014Quite a time jump and we got onto the preparation of painting the sub frames and wheels. Many hours went into this work but our pro painter made the result worthwhile.
After the basic grinding and cleaning came the primer coats and final coats.
OctoberAt this time we realized that getting the car ready for the Tokyo Auto Salon would require another body, cut in half for easy visual access to Kinokuni products.
A white donor car was found and cut in half. cut.
The frame was finally ready for a primmer coat in the summer sun..
November 17thOn it's wheels just, but oh so much more work to do. It was taken to Kinokuni where much of the show related work was done but it was show time is just around the corner.
Below is one of the many sketches of ideas that probably will not be used but provide another step to the final design. This one is a box to protect (from dust, burning rubber etc) the fuel system as there is no floor at the rear of the car.
At the same time the body, frame and roll bar all had to be placed in the best positions to accommodate everything in such a small car's confined spaces.
We started full steam ahead to get the show car ready and worry about the race car after the show. The fuel system had been made one year previously and shown in the Tokyo Show but since that time Kinokuni developed a collector tank with an in tank Bosch pump so it was back to redesign the layout plus we realized the rear suspension hoops left no space for the design of 1 year ago. System number 3 should be a go.
So out with the wires again to get the basic line layout.
More patience bending the pipes.
BUT! Due to the expected pump vibrations we added a Kevlar/Teflon and a s/s braided flex line and also to show Kinokuni's products.
A CAD drawing then inputted into the brake press bender again at Kawai Works for another fuel pump and filter mount and roll bar gussets.
DecemberIn such a small car space is always going to be a problem so many configurations were discussed. Within the engine bay lines and pipe positions took a lot of time.
The race car was taken back to Stacked's garage for final finishing on Dec. 19th.
January 2015So much midnight oil burnt by many people and the car is at last literally slid into the Kinokuni Tokyo Show booth.
With only a 50mm ride height the car was VERY difficult to slide into the pre-cut wall. That wrapped titanium exhaust caused itchy skin for weeks for the person who volunteered for the job.
MSD ignition has been set up to provide a powerful spark when the turbo is on boost.
The crew that helped put the show car together lined up at the end of the show just before the booth was torn down.
May 2015We are again back on track with the final push to have the race car on the track testing our company's products.
Final welding of chassis, roll bar, paint plus more CAD brackets from Kawai Works then it's off to Kinokuni for the plumbing, new dash and final tune before a track day.
JuneThe weather in June is getting humid and hot and the car has the extra roll bar pipes welded in. The interior is well on the way with great looking foot plates and console.
Seats are in place so getting ready for another strip down for final chassis paint.
These are too nice to put your feet on but perfect for getting your feet to pedal height.
The team deep in thought on the basic wiring layout.
The accelerator has gone through a major cut, slash and bend to allow the remote cable to control the brake bias a straight shot into the brake balance bar shaft.
Pedals are in along with the foot plates. The remote cable for the brake balance bar was really difficult to install as the cable was interfering with the accelerator pedal.
JulyWell it's getting close to having the chassis 2 pack painted so the complete car stripped to bare bones today.
Ahh! Alas the transmission mount has never been in the perfect position so out came the grinder to have it moved 10mm into the perfect position under the gearbox so that the urethane mount will support the weight without cracking...perfection.
How many times do you have to break down and reinstall components to get the fit just right in any project however when if you are lucky and there are many hands it makes light work.
AugustAnother day of wisdom from the team.
It seems that your weakest hand has the best ability to feel scratches and bumps in paint.
Also Scotch-Brite 400 grit is easy to use to get the primmer finish that will just clear the lower limit for paint to make a smooth final gloss.
I guess we learn something new every day....thanks guys.
It's now into August so the sun is beating down fiercely but work goes on getting the frame and roll bar pipes ready for painting to a show car standard so water and 600 grit finish took a long time.
The cross brace for the rear of the roll bar and the suspension rear uprights received more strength.
At the same time in a different workshop the rolls bars were being finished. The hoop behind the seat will be the frame for the bulkhead to separate the driver from the rear area. The supports for the panel and rear window were welded in and brought to the yard for sanding and primering.
Here is the roll bar hoop installed behind the driver.
Work continued till after the sun went down and got most parts ready for the silver flake paint and the several lacquer coats to make it glisten to show, 'don't touch me' quality.
The scratch free pipes are all wrapped in blankets for transportation to the painters. With only a 5cm ride height I'm going to kill the first guy who puts this car into a gravel trap.
He is going to have to dig it out himself.
SeptemberThe weather is getting cooler and the chassis is back from getting sprayed to show quality.
September 18thRoll bars looking great with the final paint and assembled ready for bolting into into the body and chassis.
Sept. 19thAfter a lot of thought, adjusting and welding the firewall is ready for preparing for paint as well as the body interior will get a splash as well.
October 8thBurning more very late night oil the body is back on the car with the interior looking like a real car.
Well we have the wheels on and the suspension tower braces so another step to the final fitting out which we all know looks easy but with so many details it takes time.
Still looking for time to work on the car but at 3 am we got this far with the final assembly. Well done guys.
Finally the car gets a ride to the Kinokuni workshops for the final fit out. Shot is passing the tallest building in West Japan at 54 stories high and mainly a hotel for the Osaka Kansai Airport KIX which is 5 km across a bridge behind the hotel.
In the Kinokuni carpark with Roberto watching proceedings and wearing his Tokyo Show 2015 Kinokuni project sweat shirt.
In comes the fork lift for a delicate lift off the truck.
The Kinokuni girl's team helping with the proceedings.
On the lift inside Kinokuni. We worked hard but didn't finish designing the many brackets for the chassis pipes, remote oil filter, clutch and brake quick release etc. so that we can have the engine purring ASAP.
October 16thDesigning the layout of pipes and lines is harder than I thought. Lots of thinking goes on with sketches to find the best solution for running the lines. Also noting the pages in the 370 page Kinokuni catalogue where to find the adapters and parts.
Also started adding discarded lines lying around the shop to better understand the space that is taken up by the fittings and how the long fuel lines can run along the chassis. Because of the upward bend at the rear and front the fuel lines which have to be threaded between the transmission mount and body they will have to be made in 2 pieces to allow assembly without distorting the original shape. The brake lines support brackets can use the Kinokuni shock mounting kit. Quick release fittings on the master cylinders and the engine fuel log.
The rear brake line runs through the drift brake and the new Kinokuni push on/off handbrake on it's way to the rear cross member to a 3 way brake brass block.
November 2nd.Many hours put in to layout the lines and hoses.
Fabricated brackets and got most of the brake and fuel lines designed and plumbed.
Within a couple of days we should have the systems screwed up and ready to test for leaks.
The water lines for the heater have been pulled off as they take up valuable space and a new pipe spaghetti has been welded up.
Fuel system wired up to test for fuel leaks and there were many.
Gasoline was all over the floor.
My hands were burning and great frustration at not having it sealed on the first try.
Bosch pumps 044 and 979's have big and small terminals.
We have a rubber silencer on the 979 so unable to see the terminal marks so we wired it up the same as the 044 with the large terminal being positive.
Wrong! The 979 is the opposite we realized an hour later by then we had fuel all over the floor from the millions of fitting leaks but happy faces.
First problem was the s/s lines had been assembled but not swaged.
Out came the lines, crimped and so the process continued.
Because of the tools available there is a minimum pipe length between the pipe flare and the bends.
The car is required tighter dimensions which apparently compromised the lower filter pipe flare quality which had to be remade.
November 20th.Found some time for more work on the car.
The fuel system is proving difficult get sealed with it's over 49 connections.
Now it is down to the swaged pipe connections that are not perfect each time they are made and will have to remake the fuel filter intake line one more time as it is the only one weeping after checking everything and made real tight.
The joint looks clean but it leaks so a new pipe is the next step.
The radiator pipes are ready for welding as are the intercooler pipes.
Another wild almost stupid but exciting external feature has been looked into to make the car stand out from the hundreds of displays at the TAS.
Not my cup of tea but we can only try and bin it if the TAS result is bad.
December 17th.Well it's down to the wire again as we are getting very close to the 2016 Tokyo Auto Salon with still a lot of work yet to be done.
It looks like we have made last minute arrangements with an Australian race team management and marketing team that will take some of the strain from our small team of staff.
Lets hope that the TAS will be a success and that Kinokuni's internet presence will help all facets of our business in the coming year.
It'll be quite a new Kinokuni presence at TAS so we hope to welcome all who can make the trip to the one of the worlds top 3 race car, custom and street tuning shows.
With over 450 booths, 900 cars plus booth babes everywhere, the show has reached it's hall space capacity.
December 19thLots of detail work going on to have the car driven into the TAS. Working hard on the plumbing and reconditioned a set of suspension uprights.
Painting in the now cold winter conditions plus lack of time between coats means that the paint finish was compromised.
December 26thWith the TAS only 3 weeks away on Jan.
14th which is the booth set day we have been getting the small bits and pieces finished step by step.
Every small piece takes so many hours.
The pipe plumbing is almost there and the basic wiring to get the car moving has started.
The Setrab intercooler finally has the end tanks in place and plumbed up.
With the large Kinokuni inventory of pipe sizes Run Max turbo hoses (P.258) and pipe bends (P.262) T Bolt clamps (P.261) the process was not difficult plus the infinite choices has resulted with a very small number of welds.
Lots of discussions on what switches and fuses (P.309) to use, how many and engine start up procedure. Battery cut off ON, Ignition ON, Primary fuel pump to the collector tank ON, Main Pump ON, Fuel pressure check.
Engine Start Push.......music starts.
We are using fuses that have an LED light that flashes when the fuse is broken.
How cool is that!
The engine and power steer reservoir tanks will go on next week as will the body components.
December 31st.The team is working hard and it's New Years Eve.
If you have no family commitments then Japan away from the major city centres is very quiet so no better time to do something with friends.
If you look closely the TAS idea for the car to stand out can be seen a little.
2016 Jan. 1stIt's looking like a finished product so Happy New Year 2016.
What are they gonna do with those pipes?
The car has a weight balance of 70/30 which will make it drive like a merry go round.
We need some serious weight at the back.
Jan. 11thThe race car is on the final stage for the Tokyo Show preparations.
Like any project it's the details that screw up a fixed time table.
A day was lost due to trouble shooting a tuning problem which finally was determined as a broken new fuel gauge.
The large black contraption in the front of the car is what we hope will provide the interest in the car and the Kinokuni booth so our fingers are crossed.
The crew are working ridiculous hours preparing the car so a very big thank you for tired eyes, cold feet, cuts, bruises and patience.
Jan. 13thWhat a grand effort from some hard working guys and tonight it goes on the truck to Tokyo. Down to the wire so lets hope all the blood sweat and tears have been worth it. Have a safe 6 hour drive to Tokyo.
January 17thAfter the successful show the crew lined up for this photo.
So many who all have done professional work to make the car very unique.
The biggest draw was the shock of having a 350hp SR20 motor in a Suzuki Jimny.
We had a lot of help from Hard Tuned whose apparel products can be seen hanging on the wall. They supplied and designed the uniforms.
Our pro driver Michelle Kimberlee tested the seat position.
On the way home the weather was not kind to us at all.
January 21stBack in Osaka Drivingline internet magazine was busy with a photo shoot on a rather cold wharf area. Thanks Jonathan for braving the elements.
Speedhunters took this photo before the car was off loaded and driven into the show hall.
January 26thOn the way back from the show Ewan had the time and energy left to take this photo showing Mt Fuji trying to hide herself in cloud and snow.
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