RS fabrications

Ellis Harvey was at RS Fabrications workshop to take delivery of his Honda CR 85.

Having been totally rebuilt the CR 85 has been prepped to the highest standard.

” Ellis came down to the workshop to get fitted to the Honda. Having grown at least 150mm  since the start of the 2009 Season, the suspension was set up to accommodate his frame & build” said Russell. ” We have put a little more preload into the rear shock and move the front forks 10mm lower in the yokes for the optimum set-up”

Ellis fired up the Honda , warmed the bike up, and practiced a few starts, to get the feel of the clutch biting point.

“We are better prepared this season” said Shane, his Dad ” and we have spares for the Honda that we didn’t have in 2009. Also, Ellis has really grown into the CR 85 over the last year and tomorrow [7/3/10] is the 1st race of the 2010 Championship”.

“The boys down at RS have prepped my ride and now its all up to me” commented Ellis. “I look out from behind my goggles at the gate and focus on the 1st corner. My goal is to be one of the 1st riders into that corner and control the race from the front of the pack!”

Watch this space for updates on how Ellis gets on riding for Banbury Motocross Club in the 2010 Schoolboy Summer Championship.

RS Fabrications will be 100% behind Ellis to give him the tools to do the job, and for a talented rider like Ellis, this is what is required. When you have a factory rider that wants to run up front, anything less than 100% will not make the grade!!

Lotus F1 commissioned CES Europe & RS Fabrications to manufacture their pit equipment for the upcoming Formula 1 Season.

Grid Trolley’s, as in the adjacent picture, have been manufactured for the Lotus team and are currently being shipped all over the globe.

With increasing Air Freight charges, the modern f1 team has to Sea Freight their duplicated pit equipment. This way they will have all the right equipment ,in the right place,  at the right time,  for that particular race.

“We have been under the gun to manufactrure the neccesary equipment to a tight timeline” commented Russell. “we had to incorporate a twin shift system to meet the demand. I was on the 6 am to 3 pm shift with Shane picking up the 3pm to midnight shift! The boys in the workshop have been under immense pressure to meet the shipping deadlines, but we have pulled it off and Lotus are that much closer to the start of the Formula 1 2010 Season!”

RS Fabrications & CES Europe Ltd, work closley together, and the equipment was custom fabricated in ‘mandrel bent’ 304 stainless steel tube, fully tig welded & mirror polished, as per the Lotus specification.

 The results are purpose built, quality pit equipment, that will support Lotus throughout testing and the  upcoming 19 race calender.

“With  the huge demands required in Formula 1, you need the best equipment, and Lotus F1 knew where they could get it”. said Shane.

As we know, races can be won or lost in the pits and RS Fabrications can manufacture equipment to get teams further up the grid.

RS Fabrications have had a long association with Tony Giles, fabricating all types of product for CES Europe Ltd.

Orders are currently being taken for Racing Car Support Equipment, and we are all looking forward to the upcoming 2010 Formula 1 Championship.

Associated Links:-

http://www.ceseuropeltd.co.uk/

Local Businessman Damian wanted to get an RS Fabrications Exhaust fabricated and fitted under his Porsche 997 Cabriolet.

Damian, a repeat customer at RS, asked Shane what would be the best configuration for the 997.

“Let me have a look and see how much space we have at the back, and I’ll tell you what I can get in there” said Shane.

The 997 arrived at the workshop and once the standard system was removed it was apparent that space is very limited on the Vehicle.

Shane arrived at a silencer design that RS have used on similar vehicles with restricted space, and fabricated twin silencer boxes with the 180 deg turn internally.

As we know, this effectively doubles the length of the silencer but keeps the outer shell to the minimum dimensions.

As previously mentioned, Damian is a repeat offender at RS, “That man has had more cars than I’ve had Hot Dinners”, commented Russell ”the first year Shane and I were in business, Damian was one of our biggest customers”

A long list of Damian’s vehicles have had the RS treatment. American trucks, cars and a variety of performance vehicles have been through the Banbury Workshop, not all for exhaust systems either.

“We have fitted various things to Damian’s vehicles over the years. The Chrysler 300c had everything. Brakes, suspension and full exhaust system, but one of the most memorable was the 300mm lift kit installed on a brand new GMC Truck. You needed a step ladder to get in the vehicle after it was completed”!! said Russell

The Porsche 997 system is a work of art.

“I purchased a pair of equal length ‘after market’ manifolds for my 997″, said Damian “and after these were fitted, Shane designed and fabricated a fantastic quality exhaust system for the Carrera S.”

Once fired up, the sound from the Porsche was incredible compared to the standard OEM System, not too noisy, but enough sound to let you know that the flat 6 is putting out some power!!

On road test, the engine seemed to rev just that bit easier and this is probably the result of the ‘after market’ manifolds in conjunction with the RS Fabrications 63.5mm Stainless Steel Exhaust System.

 The Duel, Twin Tailpipes finish off the installation, and this is probably the view that most motorists will see of the Carrera S!

Shane would like to fabricate a pair of RS Fabrications manifolds, incorporating proper racing 3 into 1 merged collectors. This would extract the final few BHP for the normally aspirated motor.

Call Russell or Shane at RS fabrications on 01295 266655 and talk to them about what they can do for your Porsche, or any performance vehicle for that matter.

Don’t delay, Get the Power!! like Damian.

Ellis Harvey is in the news again.

In only his 1st season, RS Factory Motocross Rider Ellis Harvey has finish a credable 11th in the Schoolboy Summer Championship 2009, run in conjuction with the Off Road Promotors Association..

Riding for Banbury MotorcrossClub, in the 85cc Small Wheel division, Ellis manhandled his Honda CR 85 to some blinding finishes and with consistenceycollecting points, has ended up with the 11th place Championship Trophy.

“we struggled at the start of the season with the set-up on the Honda” said Russell ” and we had to lower the suspension for Ellis. With this set-up it was difficult for Ellis get the bike cleanly off the line, but as the season progressed and Ellis grew into the bike, Shane put the suspension back up and things started to come together”.

“I had some races where conditions were particulary bad with build up of mud clogging the rear wheel”, commented Ellis “next season my Dad and the boy’s at RS have some tricks up their sleevs to get me up the front. I have the talent but I also need the right bike under me!!”

Ellis’ Honda CR 85 is currently undergoing a full rebuild at the RS fabrications facility in Banbury. Ellis strippedd the bike and the frame has been finished in black for the upcoming season and the engine is having a full rebuild with some port work to extract a bit more top end power.

“Once the bike is together,  Ellis is due to comment further at a press release scheduled for the end of February 2010″ commented Shane “and then RS have an intensive Test Program for “Gunner” to tweek the bike to his liking and get the boy mentally prepared”!

Watch this space for upcoming news as the season gets under way!!

Ellis Harvey has taken up the Tig Torch at the RS Fabrications facility.

Santa, dropped off a “Joker” welding helmet [via Russell & Sarah] at Christmas and now Ellis is under training by his Dad down a RS Fabrications.

As we all know, Shane, known as “The Terminator”  in some parts!, is the best welder in the County [and probably the whole of the UK] is the best teacher for the job.

“My Dad makes it look easy” said Ellis, “but it is really difficult to lay down a bead and be consistent. I can see that I’m going to be sitting behind this Welding Helmet for a long while!!”

“we may let him go to school a couple of days a week, but with our current workload he is going to be sitting behind that welding helmet for days on end! I hope that the Educational Welfare Officer  doesn’t catch up with us!!” commented Russell.

” Its been interesting teaching my son Ellis. Being left handed he has tried the process holding the torch on both his left, and his right hand. It looks like he may end up right handed in this application. He may also be able to do both, which is a bonus when installing roll cages in racing cars. Climbing in and out of body shells and welding on the LH & RH sides of the chassis is difficult. But that’s next week!!” said Shane.

“Watching and being tought buy the master at 10 years old is a fantastic opprtunity for any lad” added Ellis “ and he’s my Dad!!”

That Boy really is a “Chip off The Old Block”!!

Neil Freestone, Designer for Fastcar Magazine, has been painstakingly developing his Clio 172 Sport over the past 3 years into a Fast Road/Trackday Projectile!

It started with changes  to suspension [via coilovers], Image wheels, rubber, roll cage, bucket seats, but he still keeps some creature comforts, as it is still his daily runner!!

Neil has set his standards high and came to RS Fabrications, via Fred at BTM Performance, to complete Stage 1 in the perpetual development of his 172 Sport.

This involved time in the R S Banbury facility to fabricate a forced intake airbox, along with other components to maximise the available space under the bonnet.

“Picking up cold air at the front of the vehicle, combined with positive air pressure at speed, is free Horse Power!!” stated Russell ” With the Jenvey Throttle Bodies bolted to the front of the engine,  space was tight, but Fred from BTM was specific on his requirements for Neils Clio” he continued.

The standard radiator, bonnet slam panel and basically anything that was  in the way was removed from the front of the engine bay.

A tubular Bonnet Landing Frame was fabricated, incorporating the standard latch mechanism, and the Airbox was designed to fit in the available space remaining. 

Air pick-up would be from the lower aperture in the LH side of the front bumper and transfer up, through a Mahle Airfilter, to the waiting Jenvey throttle bodies.

With the available space left, a custom radiator core was made for RS, and Michael [M & M to his friends], fabricated end tanks, mounts and the complete radiator, which fitted “snugly” in the space left. 

“M & M took over all the fabrication duties on Neils Clio” said Russell “You only have to look at the finished product to see what a fantastic job he has done”. 

We can now only wait, as the Clio is being tuned shortly, but figures ar expected to break the double century mark!

Neil Freestone’s Clio [200+] Sport can be seen on Stand 2770, Hall 20 at Autosport International 2010 at the NEC.

http://fastcar.co.uk/04570735435878491400/wurz-s-clio-at-autosport.html

Associated Links:-

“Recevez la puissance” the french call it. At RS Fabrications we say:-

” Get The Power!!”

Michael Larwood contacted RS Fabrications and expressed to Russell & Shane how disappointed he was with his Clio V6 standard exhaust system and the lack of  performance after market systems available for his V6 projectile!!

RS booked the Clio in, and after pulling the stock system off the back of the vehicle , set about to fabricate a compact, stainless steel performace replacement cat back system.

First off a laser cut flange was ordered to mate up with the standard downpipe configuration and then Twin, Duel pass oval silencers were chosen in this application. With such a short silencer box the duel pass effectively doubles the length of the silencers.

Shane fabricated twin 90 degree exit pipes from the flange ,with a balance pipe between the two, and then Tig welded up the silencer boxes. The LH box was made detachable, via a laser cut 3 bolt flange, for ease of installation.

“It was a bugger to get the silencers up in the limited space available, but we wanted to make our system so that the we could retain the standard rear bumper” said Shane, “We’ve seen others, and they cut out the grid section out of the bumper to get their silencer boxes in!!” Again, the cheap option that somtimes retains the extra Twin Cat, Balance Pipe, Standard on the OEM system.

Twin 76.2mm [3.0"] tailpipes were opted for, a little larger that standard so that they fit nicely in the rear bumper apertures.

The finished system is a remarkable transformation in performance & V6 roar, that the standard system just failed to unleash!

Do what Michael did with his V6 Clio, and “Recevez la puissance!”

Visit the RS Speedlab and “Get the Power!”

Local Towcester Corvette Nutcase, Dennis Bailey, came to RS Fabrications to have titanium bypass tubes installed across the rear silencers on his imaculate Corvette.

A common modification for Vette Tweekers, which involves welding in a bypass tube so that a path is opened up across the rear titanium silencer boxes.

First thing was to make the Titanium tube. This was made by forming Ti Sheet into a round form, gas purging and welding it along its length.

“The tricky thing with Ti welding is that it has to be back purged, due to the Ti Oxide being so brittle.” noted Shane

Once the Ti tube was made the rear exhaust section was removed from the Vette. Shane then fitted the tubes from the inlet side to the inner pair of the four exhaust tailpipes.

Welding completed, the system was reinstalled on the vehicle  and then the Vette was fired up.

The transformation was remarkable, allowing the system to be free flowing and letting our the glorious burble from the Chevrolet V8.

” Just the ticket” commented Dennis “thats how a Corvette should sound!”

A keen Corvette enthusiast, Dennis has been instrumental in many Corvette gatherings around the country, so look out for him in 2010.

This modification can be done to any Corvette, whether the exhaust is manufactured in Titanium, Stainless Steel or Mild Steel.

Call Russell or Shane on 01295 266655 for further details.

Mrs V’s Cooper S was back on the Btec Dyno for some power runs with the latest version of the performance exhaust developed with Vecchio Engineering.

This final version in the Research & Development of the Mini Cooper S cat back system, has resulted in a bore size increase from 2.25″ on the centre section to 2.5″ and and increase from 1.75″ to 2.0″ on the twin silencer setup at the rear.

“Much to Mrs V’s dismay, we opted for the twin 3″ rolled in, slash cut, over her much beloved single oval slash cut! After seeing the result she agreed that maybe, just maybe they tipped the scale in sporty look.” said Russell

“Oval slash cut or 3″ Twin, either setup still look a whole lot better that those piddly little ’pea shooter’ things that come as standard on the Cooper S model.” stated Sarah V.

On the Dyno at Btec Racing the story unfolded.

“With this second phase system we saw gains in BHP and Torque again throughout the rev range. Not as dynamic as our phase 1 system over standard, but an increase all the same” stated Russell “we picked up on average 2-3 HP at comparable RPM from the Phase 1 Exhaust and another 2-3 ftlb of torque. Peak BHP of 195.5 was achieved, which was slightly down on the previous run with the phase 1, and further analysis of the power curve highlighted a spike in the Peak BHP at 6,697 RPM on the Phase 1 system. Another observation, highlighted how this system had smoothed out the dips in the power curve that were present on the Phase 1 and overall the gains made on this system are very encouraging.”

Leo Vecchio said “This is exactly what we wanted for Vecchio Engineering, and Shane & Russell have produced a Quality Performance System for the Cooper S along with the numbers to back it up. I went out with Russell for a test run up ‘Torque Hill’ and that was an eye opener to say the least!! The red line comes up pretty quick, and how he ever gets Mrs V to loan him her Mini, I shall never know!!!”

Vecchio Engineering are currently taking orders for the system, and the first production run is under way at RS fabrications.

Call Leo Vecchio on 01234 343000, and ‘Get the Power’!

Associated Links:-

http://www.rsfabrications.com/2009/08/31/mini-cooper-s-power-run-on-dynamometer/

http://www.rsfabrications.com/2009/10/25/rs-fabrications-vecchio-engineering-cooper-s-exhaust-update/

http://www.vecchio.co.uk/

http://www.btecracing.co.uk/

Jim ‘Jimbo’ Williams was back at RS Fabrications this week to have more exhaust work done to his RS4.

Sporting a white wrap with carbon roof , Jim wanted something a little different at the back of his his immaculate RS4 B7.

Jimbo opted for a quad tailpipe set-up, with two different size exit pipes. 2 x 76.2 mm rolled in and 2 x 88.9 rolled in for the sport side of the rear silencers [sport side equipped with the straight through vacuum controlled exhaust valve]. All tailpipes have been mirror polished and etched with the RS Fabrications Logo.

While it was in the RS Fabrications Banbury Speedlab, the centre box was removed from the standard system, to free up centre section flow, and 57.15mm Stainless Steel Tube was Tig welded  in its place on both banks.

The result is a marked improvement and an alternative look at the rear of the vehicle, as the RS4 normally run twin oval rolled in slash cuts on the OEM exhaust system.

Shane said “On roadtest, the RS4 had the sound of a purposeful performance roadcar, but when the ‘sport’ valve opens on those rear boxes, its in ASBO mode!!”

Jim currently runs RS Fabrications replacement downpipes, which have produced and additional 15 BHP on the Dyno [pushing it over the 400 BHP mark to 414], and he is currently still in discussion for a full blown RS system fabricated & welded by the master!

Put the RS into your RS4 today!!

Visit Russell & Shane at the Banbury Speedlab to discuss your performance requirements.

Associated Link:-

http://www.rsfabrications.com/2009/04/05/audi-rs4-v8-b7-de-cat-pipes-give-101-bhp-on-rolling-road/