RS fabrications

Local Secondary School Teacher Amy, came to RS Fabrications with the standard exhaust on her Mini One, known as Billy, in a bad state.

The original OEM silencer has problems with the mounting brackets that are welded to the skin of the silencer box. These tend to fail, partly due to the thin guage of the silencer skin, corrosion and general wear & tear.

A full stainless steel system was fabricated with duel 350mm long silencers, one in the middle section and one at the rear, and 50.8 mm tube was used to connect front to rear on the vehicle. A laser cut 2 bot flange was used at the downpipe and the performance exhaust system was then finished off with a 88.9mm rolled in slash cut polished tailpipe.

The full system, that would also perform well on a Cooper, was gas purged and tig welded. The next thing that we will be doing for ‘Billy’ is a remap, to free up BHP due to the Mini One conservative ECU map.

This will bring ‘Billy’ up to full Cooper specification for Amy.

This system is now avalable from RS Fabrications in 2 styles for you Mini One or Mini Cooper.

76.2 [3.0"] Tail Pipe Version that retails for £399 including VAT & Fitting.

88.9 [3.5"] Large Tailpipe, as seen above, that retails for £449 including VAT & Fitting.

Please note:- This is not a cheap Mig Welded item, and the pipe includes fitting at our Banbury Workshop. Please call on 01295 266655 or pay us a visit and ‘Get the Power’

Wrexham County Borough Council have taken delivery of their 2 RS Fabrications Floor Mounted Battery Recycling Collection Boxes.

Finished in Pink, the official colour for battery recycling, the collection boxes were finished off with Wrexham Corporate Branding and the standard Welsh Battery Recycling emblem for identification.

Russell & Sarah met Catherine Knight, Recycling Officer for Wrexham, at the Recycling & Waste Management Exhibition back in September 2009. Interest was shown in the FM1 Unit, with 16.5 ltr internal collection hopper, resulting in an order for 2 units for their independent evaluation.

Wrexham currently have 36 ‘Bring’ collection depots and these units will help in the collection of used batteries, which will increase in 2010 under the new government directive for battery recycling.

“We are looking forward to some good feedback, as we have had with Cherwell Council, and hope that we can supply Wrexham County Borough Council with additional collection boxes, and help them with their Battery Collection Campaign”. said Sarah

Steve Smee was down at RS Fabrications to check the progress on his Ultima/Audi RS6 conversion, currently taking shape at the Banbury workshop.

“It was good to meet with Russell & Shane again and see the progress on my Ultima” stated Steve, “these things take time to come together, and |I can’t wait to get it on MRC Tuning’s newly purchased Dyno/Rolling Road. So much time is involved in the engineering on this project, but I know between MRC Tuning  and RS Fabrications my GTR is in safe hands”.

The machined flywheel was fitted to the engine along with the CNC machined adaptor plate and everything was set to bolt the gearbox to the  engine.

The Gearbox bolted straight onto the adaptor plate and the RS6 Engine and Porsche Gearbox looked like they had never been apart.

“the next step is to get the Engine/Gearbox combination back in the GTR Chassis” commented Russell “and then comes the task of getting the turbo’s mounted with a pair of custom RS Fabrications tubular manifolds. Steve was please with the progress but also understands that it will take a lot of hours, once the engine is back in the GTR Chassis, and fabricate all the components associated with this installation”.

Shane will be fabricating the manifolds in either 321 stainless steel or Inconel [to save weight] and once the decisions have been made, we all look forward to seeing the “Terminator” welding some high quality, twin 4 into 1, equal length turbo manifolds!

Associated Links:-

http://www.mrctuning.com/

Local Company, Power Park Autos Ltd, have been working on this Porsche Boxster S and came to RS Fabrications to replace the standard rear silencer box.

Darren got with Shane and they arrived at a dual silencer box arrangement, with Twin 3″ rolled in, slash cut tailpipes, similar to the smaller OEM tailpipes supplied on this Boxster S year/model.

“we modified the catalytic convertors with extended stainless steel tube and added a 3 bolt laser cut flange,” said Shane “then we fabricated 2 of our fully tig welded silencer boxes and pieced together the complete cat back system, with mandrel bends, to fit behind the engine in the original silencer box location”.

The result is a compact Silencer setup, freeing up BHP and picking up torque throughout the rev range. The vehicle was not excessively noisy but now has a meaningful burble at idle and a growl under acceleration, synonymous with the Porsche flat 6 power plant.

The complete package can be fabricated to suit any installation or application, from racing Porsche’s, to fast road going performance models.

Contact Russell on 01295 266655 and “Get the Power!”

Raj, of NS Tuning, has been working with RS Fabrications on this big horsepower R32 Mk 4 Golf.

The R32 has previously been down to RS to have all the charge pipes fabricated for the front mounted intercooler, Air inlet pipework  and 3″ Turbo stainless steel downpipe.  

The centre section of the exhaust, also in 3″, along with the downpipe received Zircotec Ceramic Coating in Ultra Blue.

Originally running a 2.5″ Back Box with Twin Exit Tailpipes, the Golf was back in to free up some additional HP lost due to this configuration.

Shane fabricated a twin box rear section in 3″ with a full 3″ [1 into 2]  ‘y’ pipe. The original 4″ Slash Cut tailpipes were retained.

This system has freed up a further 40 BHP resulting in a 501 BHP figure for the R32.

NS Tuning & RS Fabrication are currently developing a twin rear box, twin exit rear exhaust section for the MK 5 R32 Golf.

Associated Websites:-

http://www.nstuning.com/

Local Drift Ace Mathew Pratt is having RS Fabrications build the chassis on his new S13.5 Nissan.

A Full Cage was bent up with supported turret towers in Clubman 500 Tube and the body shell has been extensivly modified to bring it up to full Drift Spec.

“I have know Shane & Russell a number of years and have also seen the quality of their work at RS” commente Matt ” the current build of Conrads AE86 is second to none and it left me no alternative in who to choose to build my S13.5 Drift Car. I have also seen other full spec Drift cars come out of the Banbury Workshop, Ian Gratton’s Honda S2000 powered AE86 and Chris Bradbury had a awsome cage installed in a Nissan S15″.

Wheel arch tub modifications will be fabricated for wheel clearance at the front and lip extensions fabricated at the rear to accept the new bodywork.

Matt can often be seen around Banbury with smoke pourning off his rear tyres!!! 

“Smokin Skills”- Harmful to one’s health? No way!!

Drift On Brother!!

Follow Matts blog on the build of his S13.5:-

http://projectrs13point5.blogspot.com/2009/06/plan.html

RS Fabrications, in association with MRC Tuning, are performing a transplant on a Ultiima GTR.

The Ultima, originally running a Chevrolet V8 with Porsche gearbox [mounted upside down], is having an Audi RS6 V8 twin turbo installed.

“after the engine and gearbox were removed, we set the donor RS6 engine on the surface table and started on the engineering required to mount the gearbox to the Audi V8. A new flywheel is currently being machine and we had to do some reverse engineering to manufacture an adaptor plate to mount the two together. Once we have the transaxle unit together, with the new flywheel, clutch and adaptor plate, we will be mounting it back in the Ultima Chassis”. said Russell

Once the engine mounts have been fabricated and the engine & gearbox are back in the chassis, work can proceed with manifolds & turbo mounting, along with water system & intake air cooling.

“With Doug and MRC Tuning extracting big HP from the RS6 unit, the Ultima will be a formidable tool“, continued Russell ” Shane will wave his wand, well TIG Torch really, and produce a full racing  exhaust system on the beast. Once competed it will certainly be an interesting ride up Torque Hill!!”

Associated Sites:-

www.mrctuning.com

http://www.ultimasports.co.uk/Default.aspx

Mrs V’s Coopers S was back in the workshop to have the “Phase 1″ Vecchio Engineering performance exhaust system fitted.

The stainless steel system consisted of CNC 2 bolt flange mating to the original manifold & catalytic converter on the R53 Cooper S. The center section has a single silencer box with 2.25″ bore entering into a pressed 2 into 1 merged collector. This then feeds twin 1.75″ tube and oval silencer boxes at the rear. The twin pipes then exit the Cooper S in the centre of the vehicle, and in this application a single slash cut oval tailpipe was used.

“Mrs V is very specific in her requirements and the Oval Slash Cut tailpipe is a pleasant change from the normal twin Cooper S set up” commented Russell ” when we have finalised our design we will be offering the system with both Twin 3″ Slash Cut and the Oval Slash Cut, as seen here on Sarah’s R52 Convertible”.

It was back to the rolling road at Btec Racing for some power runs with the Phase 1 System.

The Coopers S picked up 7 bhp peaking at 199.5 @ 6,697 rpm, but more importantly it picked up 8 ftlb of torque throughout the whole rev range.

“its very encouraging at this development stage” continued Russell “Shane is currently fabricating the Phase 2 system at the workshop and we are going with a 2.5″ centre section with a 2 into 1 racing merged collector feeding duel 2″ tube and twin Oval Boxes at the rear. This system will run twin 3″ Slash Cut Tailpipes, more in keeping with the Cooper S theme”.

R & D is also underway on a R53 Mini One/Cooper free flowing stainless steel exhaust system. This will be offered in Twin and Single silencer box configurations.

Associated Websites:-

http://www.vecchio.co.uk

http://btecracing.co.uk

David from Vision Moto came to RS Fabrications with his MV Augusta “Carbon” Brutale.

Vision Moto supply a wide range of performance parts for MV & Ducati Super Bikes and David had put together a full Titanium Exhaust System on the immaculate Brutale, with a Carbon “short GP” Silencer and had no way of connecting the 2.

“We got the Brutale down to the workshop and had some titainium bends manufactured for us” said Shane, ” we then fabricated a 2 into 1 collector for David.”

Titanium Spring retainers were added along with springs and the Ti Collector was fitted to the Brutale.

“Its light and the fabrication is excellent, but this is what I have come to expect from Shane, Russell & RS Fabrications.” commented David “I also have a full works “Martini” Integrale Evo II that I have some plans for, so that will be the next project with RS and the boys in Banbury!”

Vision Moto can be found at:- www.visionmoto.net

The Recycling & Waste Management Exhibition took place at the NEC, Birmingham this week and RS Fabrications participated with a Stand exhibiting their Battery Recycling Collection Box.

The show, over a 3 day period [15, 16 & 17th Sept] had many of the industries suppliers and this was a 1st for RS Fab.

” we displayed our product and generated a lot of interest in our standard Battery Collection box” commented Russell, ” We also had on show prototypes of a smaller round collection units suitable for small companies to collect batteries  from their workforce to support a  green/recycling challenge. This unit can be supplied in any colour and can even incorporate company logo’s etc.”

In the UK, 660 Million batteries end up in landfill and currently only 3% of all batteries sold are recycled. With the Government Directive coming into force, huge improvement is expected next year, and RS Fabrications  can provide a  tried & tested collection box to fit in with any recycling requirements. Cherwell Council, currently operate 30 Blue Collection Units at 30 sites across Oxfordshire and a further 8 Green Units at their County Collection Depots.

There is confusion in the industry at the moment in regard to the value of dead batteries. Some say they can be worth as much as £200 per Tonne, and others say a lot less!

With Shane Harvey overseeing duties at the RS Fabrications facility, Russell & Sue Lewis [Public Relations] opened the show on the tuesday. The wednesday & thursday duties were handled by Russell & Sarah [Mrs V].

” It was good to meet with  potential customers and get their feedback and our new counter top model generated a lot of interest from companies just wanting to participate in battery recycling” said Russell ” We had a lot of interest from Schools, Universities, Hospitals and Rail Networks, as well as individuals. With the implementation of the Government Directive, it is anticipated that tonnes of batteries will be collected in the next year”

RS Fabrications are happy to adapt the design to meet any requirements, such as provision for wall mounted units. Contact Russell on 01295 266655 or via e-mail:-  russell @rsfabrications.com