RS fabrications

Jon Stangle, of Stangle Preparation Ltd, last campaigned his Darrian T90 on the Killarney International Rally of the lakes in 2009.

The T90, at that time, was running a Cosworth BDG on injection, but since then Jon has installed a Honda S2000 lump.

The engine was mated to the Hewland  Gearbox, designed and modified  by Jon himself to be a fully sequential unit.

Jon, local to Banbury, came to RS Fabrications to have a set of primaries fabricated for the Exhaust System.

Using some of Jon’s original system, principally the collector, the equal length set of primaries was designed to incorporate the collector supplied and mate up the the single silencer box at the back of the Darrian. Jon is to have the completed system ceramic coated prior to the completion of the vehicle.

On a laser cut Stainless Steel flange, Andor was responsable for the CAD work, and Shane, yet again, produced a fantastic set of primaries for the Darrian T90.

If you are interested in the Cosworth BDG Engine from the Darrian, it has been rebuilt by John Wilcox and it is currently up for sale.

http://www.wilcoxengines.co.uk/

Please contact Russell on 01295  266655 for further information.

News is getting round that RS Fabrications is the place to bring your Porsche for a complete performance exhaust or a modification to an existing item.

First up was Henry, a Warwickshire Businessman, and he wanted modification to the exhaust on his GT3.

Henry was very specific, and wanted the the exit pipes on the vehicle ending  with twin 3″ tailpipes, on each side of the  rear bumper apertures, common on full blown racing cars.

This extensively modified performance vehicle was in the RS workshop for only 3 day for the mods, and when Henry came to pick up his 997 he was over the moon with the results.

Repeat customer, Chris from Stoke, brought his recently purchased Boxster S RS 60 Spyder to RS Fabrications with a challenge.

Chris wanted a RS Fabrications exhaust that incorporated the exhaust valve that come standard on the Boxster S RS60.

The valve, operated from a switch on the dash, means that you can have the exhaust in regular or sport mode. In sport mode the valve opens and lets the exhaust gases pass with less silencing, opening up the glorious sound from the flat 6 engine.

The standard Porsche Sport system was removed from the vehicle and the valves were removed.

Custom silencer boxes were fabricated incorporating twin duel  path silencer boxes, with one path silenced the other unrestricted in each box and operated by the Sport valve from the OEM system.

New secondary pipes were pieced together using 2.5″ 316 Stainless steel mandrel bends with 3 Bolt laser cut flanges. These connect the manifolds to the RS Fabrications silencer boxes.

Twin 3.5″ Rolled In, Slash Cut Tailpipes, finish off  the exhaust at the back of the RS60 Spyder, and the results phernominal.

“Its good to have the option of the silenced or straight through silencer boxes at the touch of a button”, commented Chris“its like having two exhaust sytems for the price of one”.

“We have produced a well balanced system for the RS60 Spyder and Shane, once again, has put together a quality exhaust for Chris.” said Russell

Next in was Paul fom Leicester with his 997 Carrera S.

Paul opted for the full RS 997 exhaust system.

Paul supplied a pair of after market manifolds, that would be fitted to the vehicle, prior to installation of the RS 180 degree Silencer System.

With the 180 degree silencer boxes and 100 Cell FIA approved Catalytic converters, this option is offered with a range of exit tailpipes and Paul chose twin 3″ &  3.5″ Rolled in type on each side, to retain the standard look at the back of the Carrera S.

With limited space at the back of the 997  it was difficult to get the 100 cell Cats in, but with a selection of 2.5″  316 Stainless Steel bends, Shane put together the cross over pipes that incorporated the Cats. 

After initial road testing, Paul’s Carrera S was delivered to MRC Tuning for a re-map and run on their Dyno, to extract the best from the package.

http://www.youtube.com/watch?v=s2KfrKWmbOE

http://www.mrctuning.com/

Next month RS Fabrications have a classic 911 Turbo in for a full system so everyone is waiting to get their hands on the iconic Porsche down at the workshop.

RS Fabrications can help with all your Porsche Exhaust requirements, from classic 911 to current GT2/GT3 and full racing spec models.

Call Russell or Shane for availability and get your Porsche booked in!

Cherwell District Council came to RS Fabrications with a vision for Banbury to celebrate the 2010 World Cup Tournament.

They wanted a 2m Football Sculpture erected on the roundabout directly outside the Spiceball Leisure Centre. The enquiry was 2 weeks prior to kick off, so time was of the essence!!

Originally the concept for the sculpture was to have an Aluminium ball fabricated from 2 Hemispheres, but upon research only a 1.5M ball could be metal spun and welded, but also the parts would have  a 30 Day lead time from a Metal Spinning Company.

Russell Contacted Tim Green at the council and offered an alternative design for the sculpture and Andor created the CAD files to show Tim how the sculpture would look. Andor even went to the lengthof downloading the actual roundabout from google streetmap,  and placed the image of the ball in the centre of the roundabout to show what it would  look like.

Wednesday 2nd June, Tim and his associates liked the concept and the go ahead was given to quote on the manufacture of the World Cup 2010 sculpture, but one stipulation was that it had to be installed before the tournament began! The Tournament was due to start on Friday 11th June 2010 !!

Andor was back on the computer again to produce the drawings for the laser cutting and fabrication. The Sticker Man, Gary from Display Graphics, was contacted and by Monday 7th everything was in place for Tim Green to place the order!

Monday 7th Noon, Tim Green pulled the trigger and the race was on for Friday!!

Parts ordered, laser cut, picked up, fabrication began! At one point Shane did say, “Have you lost your frigging mind Russell!”

Once parts were welded & assembled, it was off to Power Park Autos for the white finish in powder coat.

Once back at RS Fabrications, Gary & Sue from Display Graphics sorted the football image decals, supplied via CAD files from Andor at RS .

Things were coming together for the World Cup 2010 deadline!

Coming Home, we’re Coming Home!!, or down to the Spiceball Roundabout in this case!!

On the Spiceball roundabout things progressed!

Installed 1.5 Hours before the kick off for the Tournament, the sculpture was situated on the Spiceball Roundabout, and is a true testament to RS Fabrications ability and quality associated with metal fabrication in a short timeline.

Cherwell Council intend to use this sculpture for forthcoming sports events, Tennis, Cricket, Golf, or anything that Banbury,  the community, want to get behind!

Visit us on you Tube:-

http://www.youtube.com/watch?v=T6unOYbX1OI

Come on Banbury, Come on England!!!!!!!!

Associated Websites:-

www.displaygraphicsuk.com

www.powerparkautos.co.uk

Repeat customer, Rob Waters, dropped off his Sierra Cosworth to have a 3″ exhaust system fabricated at RS Fabrications.

Rob’s Cosworth is currently undergoing extensive modification, with a full rollcage and various other performance items, Rob called Russell and booked the cosi in for a full 3″ stainless steel exhaust system. The vehicle was delivered with a 3″ turbo down pipe and it was just a matter of fabricating a centre silencer box  and rear oval silencer to fit under the lowered Sierra.

With silencer boxes of this nature, power loss is kept to a minimum, and the exhaust noise is controled to an acceptable level for track use, under 98 Db being the target value.

Look out for Rob in the Kent area, but the only part you are likely to see is the rear end of his cosi, spitting flames from that 4″ tailpipe!!

Darryl, local High Wycombe Heating Engineer, came up to RS Fabrications, with his wife Wendy, to visit the facility and see what  RS Fabrications could do for his pride and joy, a 1991 Ford Granada Cosworth.

Darryl has upgraded his ride over the years, and he is very specific on the parts required, considering the current tuning on the vehicle and what is planned for the future.

Equal length primary manifolds were specified in 2.0″ stainless steel with racing merged collectors leading into twin 2.5″ downpipes. Manifolds would be ceramic coated with spring retainers.

A three Silencer Box Exhaust System would then feed into Duel Twin Staggered Oval Tailpipes at the rear of the vehicle.

The 1st silencer box is twin 2.5″ inlet and has an internal 2 into 1  collector and exits at 3.0″.

Centre box is 3.0″ in and 3.0″ out and the rear box is 3.0″ in but also has an internal splitter, splitting the exhaust gases back into a twin 2.5″ section. This section then feeds the Duel Twin Staggered Oval Tailpipes, as previously mentioned.

The completed system has been fabricated without any compromise.

Shane struggled to fit the equal length  primaries in on the RH bank of the motor, due to constrictions associated with the steering column, oil filter, chassis leg and just limited space available, but managed after couple of minor exasperated moments!

New highlift cams are in the pipeline for the Granada, along with a supercharger, so Darryl will be back to RS for a front mounted intercooler and charge pipework. Watch this site for updates.

Work on Steve Smee’s RS6 Ultima GTR continues.

Steve is itching to get his hands back on his RS6 twin turbo Ultima GTR, as progress continues at a slow pace due to the complexity of the installation.

“Everything from the cockpit back has had to be modified” said Russell “and the brunt has been the chassis modifications required to fit everything in!”

The engine & gearbox has been in & out of the chassis at least a dozen times, over the past few months, this was to sort out the finer details of the transplant”. 

“Shane has also had a nightmare fabricating the manifold on the right bank of the RS6 lump, due to space limitations. After he got the primaries in he then had to try and get the gearshift linkage back in place, so a new bracket had to be fabricated and welded to the chassis to re-rout the linkage”

The manifolds, constructed from 321 custom stainless steel bends, will be ceramic coated prior to final installation and the racing  merged collectors feed the turbo’s, which have been located above the gearbox.

Silencers are currently under fabrication and again, these are tight with the turbos and the rear tail section on the Ultima

The original twin fuel tanks were also removed and a single item fabricated in front of the engine. This was to open up space in the side pods for twin intercoolers and ducting that will be required for the RS6 Twin Turbo setup.

Doug, down at MRC Tuning, is also anticipating the ultimas arrival, and getting it strapped onto the their new Dyno.

Watch the RS Fabrications Website for further updates as the project comes together.

Associated Websites:-

www.mrctuning.com

Local Businessman, Pete White, came to RS Fabrications to have Stainless Steel Sidebars fabricated, polished and fitted to his VW LT35 Van.

A practical solution to a problem Pete was having at the local market associated with his business, Orchids by Peter White. Trolleys moving plants and equipment constantly knock the side of the delivery van and these bars stop the intrusion of the trolley base from going under the side of the vehicle. They are also a tidy addition to any van, custom, delivery or otherwise.

While in the workshop having the sidebars fitted, the wheels were removed, prepped and re-finished in gloss black at RS Racepaint. Pete looks after his vehicles, and he likes to keep them in practical and presentable conditio as they are used frequently on his trips to Holland.

Call Shane or Russell for any of your van requirements.

Assiciated Website:-

orchidsbypeterwhite.co.uk

RS Fabrications Apprentice Ben Scott, on the right, and James Matthews completed their 1st full exhaust system together on the RS Fabrications Audi A4 Avant.

Ben Scott, known as Ben 10 to his colleagues, has recently joint the RS team and has been signed up as the RS Apprentice due to his fabrication skills and commitment to engineering. Ben 10 is currently studying Motorsport Fabrication at OCVC Bicester Collage and has been top in his group in Tig Welding & Sheet Metal Fabrication.

James Matthews, on the left, has recently joined RS Fabrications after completing his apprenticeship with Prodrive.

James has become a great asset, bringing his knowledge and skills to the company and he pulled out all the stops during the thrash to get the pit equipment to Lotus F1.

Russell’s 2.0 Diesel Turbo A4 Avant has recently been re-mapped at MRC Tuning, taking the Audi from 170 to 220 BHP.

Doug & Minea at MRC suggested that the vehicle would benifit from a larger bore exhaust system’ and after this the map could be “tweaked” to extract a bit more power!

“We decided on a 2.5 inch Turbo downpipe leading into a twin silencer system with a 1 into 2 split at the rear. Twin pipes run to the rear feeding into twin 3″ down-turned sniper tails” said Russell. “I wanted Ben 10 & James to build the complete system, under the guidance of Shane, and the lads have done a fantastic job”.

Ben 10 & James worked closely together to produce this performance system and the quality shows through. Shane & Russell look forward to working with them on future projects

Shane & Russell have decided to sell their trustee steeds, a Kawasaki ZX9R and a Virgin Mobile Yamaha R1.

Both have been extensively modified with Shane rebuilding the ZX9r from a bare frame up. Sporting a custom4 into 1 into 2 twin silencer exhaust system the ZX9r also carries black satin powder coated frame with gold & polished 3 spoke wheels. Every stainless steel nut & bolt has been polished on this bike and the paintwork has been finished to the highest standard. New racing clutch and EBC Brakepads were also installed.

“We only managed to get out a couple of time last year so we are both not really getting much use out of the bikes” commented Shane “and we have other projects in mind for this year!”

“I took the R1 home when it was first finished ” said Russell, ” We then managed to get away for a weekend trip to the South Coast and clocked up about 500 miles. I think Shane has ridden the R1 more than I have!”

Russell’s R1 was rebuilt and the paintwork finished in the RS Racepaint Shop. Sitting on 5 spoke Carbon Fibre Wheels with Dunlop Rubber, everything on the R1 has either been modified or updated.

Ohlins Rear Shock Absorber and Steering Damper compliment the upside down front forks. Fully adjustable Attack Rear Sets help with the  rider positioning on the bike, and a Harris billet fuel cap sits on top of the fuel tank.

Frame, finished in satin black and all engine covers refinished in gummetal grey under the Virgin Mobile Racing faring.

The Yamaha also runs a full RS Fabrications Titanium exhaust system,  and a short Ti Akrapovic silencer can.

New EBC Wavey Discs, front & rear, with EBC Brakepads sort out the braking.

The ZX9R is up for £3200 and the R1 £5500 [with the spare original 3 spoke wheels mounted Dunlops and standard brake discs]. Alternatively the R1 can be purchased with the original 3 spoke mag wheels only, for £4200.

For more information, call Russell or Shane on 01295 266655

Alan has been in contact with Russell at RS Fabrications for a rear silencer box for his fantastic Slammed Turbo Golf Special.

The Golf has received a lot of attention to bring it to its current state. Sitting on air suspension, the Golf came from Greg Howell’s place in Southam wearing thisimaculate paintjob, straight out of the end Gregs gun!

With a long list of modified components in this build, Alan had been speaking to Russell for a long time with a view to getting the Golf down to RS for a Custom rear silencer box with sniper tails.

Shane prefabricated the Stainless Steel silencer, and when Alan’s Golf arrived at the RS Speedlab,  fitted the fully tig welded item under the back of the Vehicle.

The  descreat Sniper Tails are twin 2″, slash cut, and you can just see the slash cut tips, just pertruding below the rear valance on the rear bumper of the Golf.

“It’s a good clean look that enhances the finish at the back of the Vehicle” Commented Shane.  “The last thing that you would want to see is some half arse pipe protruding from a silencer box, mig welded up, and poking down below the car”.

Look out for Alan’s Golf, as we are sure its going to be a big hit on the VW scene this year!