A Visit to D-SPORT: CNC Machining and Engine Work

We recently had the opportunity to visit D-Sport, a company that specializes in custom car builds and engine work. Our guide took us through their facility, showing us the intricacies of their processes and the tools they use to create high-performance vehicles. One of the first things we saw was the CNC machining process. The machine, which is essentially a computer-controlled cutting tool, was used to cut out a three-inch piece of material from a block of wood. This may seem like a simple task, but it's an important part of the CNC machining process.

Our guide explained that this specific job was for a client who needed a custom part for their engine. The part had to be precisely 3 inches long, and the CNC machine was able to achieve this with incredible accuracy. The guide then explained how they used software to tell the machine exactly what direction it should move in order to create the desired shape. This process may seem straightforward, but it requires a high degree of precision and control.

After completing the CNC machining task, our guide showed us the engine work that D-Sport is currently undertaking on their latest project, which involves a custom V12 engine. The engine is being built for a client who wants to create a unique vehicle for SEMA. The guide explained that they are using a combination of specialized tools and techniques to build the engine, including honing the cylinders to ensure perfect sealing.

The goal of this project is to create an engine that not only looks impressive but also performs at its best. D-Sport's expertise in engine work is evident in their attention to detail and commitment to quality. Our guide showed us some of the specialized tools they use, such as custom-made valves and ports, which are designed to optimize engine performance.

One of the most exciting aspects of this project was the prospect of reusing the cylinders that were being installed. This not only saved time but also money, as it meant that D-Sport didn't need to purchase new components. Our guide explained that they had been able to reuse 48 out of the 48 valves required for the engine, which is a significant cost savings.

The project's deadline is approaching rapidly, with just 61 days left before SEMA. This means that every moment counts, and D-Sport must work efficiently to complete the task on time. The guide explained that they are racing against the clock to get all of the parts in order, including the pistons, which may take up to eight weeks to produce.

Despite the challenges ahead, our guide was optimistic about their chances of meeting the deadline. They have already started working with a supplier who can provide them with custom-made rods at an accelerated rate. This means that they will be able to complete the project on time and get it to SEMA in optimal condition.

As we concluded our visit to D-Sport, our guide invited us to share some exciting news about their upcoming projects. They have recently ordered materials for a new valve job, which will involve honing the ports to ensure perfect sealing. The goal is to create an engine that not only performs at its best but also looks impressive.

The company has also been working on a custom insta 360 car set, which they plan to complete soon. They are offering an exclusive deal for their followers, including a free selfie stick or lens guard with the purchase of any camera equipment. This is a great opportunity for D-Sport fans to get behind-the-scenes access to their latest projects and gear up for SEMA.

As we left D-Sport's facility, it was clear that this company is dedicated to pushing the boundaries of what is possible in custom car builds and engine work. With their expertise, attention to detail, and commitment to quality, they are sure to deliver an impressive vehicle at SEMA.

"WEBVTTKind: captionsLanguage: enDDE fam welcome back what's up guys we're back again what's going on Mike d-sport has some news for us so we've got good news um I don't know yet they said that they checked a bunch of stuff they measured everything out and they want us to go over there to get an update and I hope that it's good news we have 61 days left in telsema an insanely short amount of time oh geez so oh oh no no I want to love catboy so like I said we've got 61 days left Damon's in town now means that uh we're gonna be a little distracted here but we have a lot more work to do on the car before we go over to d-sport today we're gonna get cranking on that and uh we got to fix some stuff that Damon broke yesterday when he jumped in the car for the seat fit that tube is uh no longer packed in place remember when I said that this pedal is so much better than the factory throttle pedal well it is it's a lot stronger but it doesn't fit in this chassis like basically resting against it so even if we chopped all this out we still wouldn't have very much travel so we're gonna use the stock pedal after all stock pedal goes back in and it's a nice little mounting position and now we can shift everything back move it over a touch to do that we're actually going to cut this tube out unbolt the pedal assembly and make another flat plate here with some slots that will move further back so we can position everything test fit it make sure we like it and then we can figure out how to do the final mounting we move on with a roll cage fabrication on a very high horsepower car you don't want to have three quarters of an inch of pedal travel where it's zero throttle and 100 throttle makes the car so hard to drive so you actually want a throttle pedal that has some travel to it we're gonna throw the stock pedal back in there make everything fit a little bit better so we redesigned that plate we'll cut this new one out on the plasma table tack it into the car again let Damon sit in the car again later on and then we can move forward so we got the pedal assembly bolted onto our new plate here that has the hole slotted about 40 millimeters further back we're also shifting it slightly closer to the throttle pedal since we have more clearance there with a factory pedal than we did with the Tilt and pedal so able to get this the pedals lined up actually even better a little better for heel toe foreign back in the car with the factory throttle pedal I'm actually kind of tippy-toe right now so if I was going to push the brakes my leg is completely extended flat which is a good thing being that we are in the seating position for Damon he has longer legs than I do so he will have a little bit of Bend at his knees that'll be perfect when I move the seat forward into my position probably right around here oh there's the cap the Damon shot off yesterday when he stopped on the brakes with nothing connected there's a little dust cap on the master cylinders to stop stuff from getting in there so the factory throttle pedal feels okay it is a bit soft throw on this is okay so we have a decent amount of travel with the tunnel and the throttle pedal positioning is actually pretty good so three quarters over on my foot throttle pedals down side of my foot is right near the side of the firewall yeah this looks good I think the only thing we have to check now that we moved the pedals over closer to the center the steering column you might have an issue on the other side looks like from the center of my driving position it will go right past the brake pedal which should work out that's going to work I'm just going to double check the other side of the firewall to make sure there's nothing that's going to obstruct us there but I think we can get a steering column in here right next to the side of the brake pedal will fall right there I feel like the steering is really centered up which is nice some cars you have to put the steering wheel offset a bit and it feels weird when you're driving it other cars actually tilt the steering column at an angle and that also feels weird because your driving position and where the steering wheel is sideways one way or the other so it just has kind of an odd feeling in the car the old school cobras are like that you actually sit super sideways in the car actually this way because the trans tunnel is so big and the inside of the car is so weird but the steering wheel is pointing one way and the pedals are pointing another way and you're kind of like crossed up in the car it's a really interesting car to drive I think we'll probably shift the brake pedal over since it's adjustable we can actually move these bolts over to the side a little bit and shift the pad over so this is a little closer this is a bit of a reach there you can do like a big twist over but I like to do more of the Roll the style heel toe that'll give us a little more room on the clutch pedal as well so your feet aren't touching in between here and overall I'm liking it this feels good as far as positioning goes the steering wheel to shifter this is looking pretty good I think this is right about where the shifter is going to sit we may have to cut this out a little more that is not a big deal this will go right around there steering wheel nice and centered up and then we have a good amount of room here to put our e-brake in e-brakes I like to have a little bit more forward so the transition between the steering to the shifter doesn't get basically interrupted by that right in the middle it also gives you a little better leverage if you're too hunched back here you don't really have you know good pull a good feel so having it kind of extended arm almost to grab and pull it's pretty ideal and I think that actually is going to work out really well we have a good amount of room in between the shifter and the steering wheel it's gonna work it's gonna work really good you excited Tim I'm excited mark and dealing with this F12 build ordering all the parts not having any money you know what I just need to take a break it's time to place a video games oh yeah all right so most of you guys are already familiar with the insta 360 X3 camera but they just came out with this brand new three suction cup vehicle mounting system and it makes putting your insta 360 onto your car your truck whatever it is so easy and it's stable this is a one-person setup it literally sets up in a minute and you're good to go this X3 is brand new half inch sensor captures the action in Vivid 5.7 K 360. choose your favorite angle after the fact with easy reframing tools in the AI powered insta 360 app all right so we had it on the back of the car now we're gonna put it on the front of the car and just get a completely different perspective a bit of a unicorn shot the insta360 triple suction cup car mount provides a unique third-person perspective when filming your ride an all-new revised design provides a solid sturdy mount for your X3 ensuring your car content looks seriously Next Level while guaranteeing a safe and stable support for your camera it's the 360 X3 camera paired with their brand new triple suction cup vehicle mounting system it's an absolute Game Changer complete your insta 360 car set now with the newly released multi-functional durable branded suction cup combined convenience and quality purchase your insta 360 camera and essential accessories in one easy step click the link in the description to get an exclusive offer just for DDE fans 25 off the 1rs a free selfie stick or a lens guard a free 128 gigabyte SD card for the first 50 buyers don't miss out on this exclusive deal just for the DDE audience yo but what time is it oh oh man all right so now that I'm happy with the pedal box location we've decided to go with a factory pedal we can move on to some other roll cage Fab and the next tube that I want to do is the header so this is a very important tube because it ties these two bars together without this tube across here if the car did roll over this tube could fold in very easily it wouldn't have a lot of strength so it could just basically Crush down fold in that's not the idea of a roll cage you want to tie this in but we also want to make sure we get it up as high as possible even though it is a bit further than where the driver is sitting there is a chance that the driver's head or passenger's head could make contact with that bar so we're going to try to put it in this little Groove here just like we did with the a-pillars on the side it's on a weird Bend it's next to two band it's going up and it's going to be rotated about 45 degrees that way so I'm going to make it out of some thin wall cheap tubing first cut and Tack together just like we did with the template for the a-pillars measured across here it's about 43 inches I'll mark that out on a tube cut that and then I have a piece of scrap here that had a 17 degree Bend in it it actually looks like it fits pretty good so I'm going to try this first but keep a longer piece of tubing on it and then see if I can get it right the first time so I'm just going to remake this I've got 43 inches across and that's giving myself probably about an inch and a half extra on each side so we'll cut that at 43 and then we'll chop the tube in half that way I can basically mirror it and do both bends both notches just keep trimming down that Center to get the tube to be the exact right length then I can get the measurements off of that and make it properly the first time with the correct piece of tubing the reason that I'm using this tube it's thin wall tubing it's very easy to work with it cuts quick it bends quick it's also it's very cheap so this is about I think it's less than two dollars a foot where the other stuff is four times that much this is just the more economical and easier way to go to mock everything I'll start chopping this up Notch it bend it fit in the car see how we're looking all right so we got our tube marked out where it's going to get bent and where the notch lands this is measured exactly I've got basically a punch Mark where the hole saw is going to go and then I have the Scribe line this way for the Bender so it rotates right and the start of the bend now that I have all this measured out when I make the other part the correct one it will be exact I'm just going to confirm that the notch is correct and yep that looks good so I can put in the Bender now bend it 17 degrees on this Mark do the same on the other side pop it in there and then all I have to do is basically trim this down get it the correct length end to end tack it together and we will be good to go to make this out of the correct roll cage tubing so I just pulled it out of the bender and I just want to confirm that the bend looks the same on both of these because this one was really hard to measure the bend couldn't get an accurate measure off the back of the tube because it was smashed this I couldn't tell if it was really at the end of the bend or if this was cut properly then I'll put this piece inside the car make sure it looks good there and then I'll bend the other side all right let's see if this thing fits see that looks pretty good all right I will bend the other side up match this one so now that we got both tubes bent and notched measured the roof to find the center of the car marked that I marked each tube at the center we're gonna pop those in now if it all fits well we'll tack it together and we can make the correct piece all almost spot on there I think it might need to come back a little more which means it needs to get a little shorter yeah I don't know actually that's pretty much it pretty good I think it just like the middle yeah it might take like a millimeter off maybe two millimeters off but the notch fits really good everything looks really good I think I might just sand this down a little bit it should be good to go now that we have both these tubes trimmed up I took just a little bit more off of there probably about one to two millimeters as a pillars come up we were just a little too far forward so we'll get that Twisted back a touch and we're good to go we're gonna attack it in place it's one of the other tubes that finishes off the main the basic structure of the cage so it'll be good to get this out of the way then we just have door bars left down tubes harness bar diagonal a couple tubes here and there we're almost done right all right see the fits uh it looks pretty good it is nice and tight so it's falling forward because the a-pillars move out but when it's in the right spot I think it looks pretty good all right so the test tube fit perfectly now we can cut it out of the proper tubing mark it out get all of our bends in it notches everything ready put it in the notcher cut those notches bend it up put it in the car tack it in place and then we can go over to d-sport and check in on what's going on inside of our engines not straight anymore I missed I completely missed the no look fast I know like it did not work for me this time I missed it by an eighth of an inch my turn come on all right first try first first second try I got it that time boom first time all right that looks really good I'm happy with that we are moving along with this project 61 days left and we have a half a roll cage and a pedal assembly I'm not even working on this car and I'm stressed out now that we have our header bar done and tacked in place huddle assembly mocked up in the correct position now now I can move on with finishing up these boxes so they're going to get shortened a bit so we have less intrusion basically into the driver department for driver passenger ankles and all that shorten that up finish that plate still have to make door bars but that's going to be I might even run tubes through the front firewall to the shock Towers but I want to wait until we have the engine in before I do any of that stuff we may add gussets there's a lot of other stuff that we can do but the main parts that we need to finish are the diagonal bar which goes from the passenger side uh bottom of the main hoop up to above the driver's head and then harness bar we've got the two down tubes that are coming off of the main hoop basically to the rear shock Tower area even though this isn't a McPherson strut car so it doesn't really have a shock Tower per se but that's a strong point where we're going to land it that's all stuff that we have to do but the first thing that I need to figure out is fuel system placement fuel cell we need to find a good location for that measure the amount of space that we have order one hopefully that's off the shelf and hopefully that's already Complete because if it's a custom fuel cell or one that's not in stock it usually tends to take about six weeks that would not work well with our timeline here's the factory fuel cell that we took out of the F12 so it's actually a very nice piece it's all aluminum fits in the chassis really well but now that we've added the Quick Change diff we had a problem with contact with the bottom of this area here it's also I think this thing holds 24 25 gallons something like that it is a lot of fuel and we do not need that much fuel for this car so an option is to cut this thing down basically chop it and use a section of it but the main problem with this tank is that it is not made for a race car so it doesn't have baffles inside it doesn't have a surge tank which means something that is holding the fuel and not sloshing around also inside of a fuel cell there's foam it's a an open cell foam that slows the fuel down from sloshing side to side so it keeps the fuel pretty level on the tank and you can run it down fairly low where a lot of cars from the factory once you get below a half tank or maybe even three quarters of a tank and you're on track and all the G loads are basically making the fuel slosh side to side you're going through the s's you're on the brakes you're on the throttle and that fuel is basically just sloshing around everywhere in there and that could be a huge huge disaster especially on an engine like this twin turbo V12 1500 horsepower there is no room for air in the tuning and if the fuel was sloshing around and the fuel pumps picked up Air instead of fuel and pumped that in the injectors would basically fire half fuel half air it would run lean and we could melt a piston it could detonate and spin a rod bearing and could throw a rod it could crack a block crack a sleeve the biggest and most important reason that we're putting fuel cell in is for the baffling system and for the safety of that fuel cell so this tank is just a layer of aluminum it can get punctured and basically split open and spill all the fuel out the fuel cell is shell and aluminum shell and then inside of that shell is a bladder made out of a special material sometimes it's almost like a Kevlar type material if it gets punctured on the outside that shell on the inside collapses twists and it is very puncture resistant so most likely you can have a car that's wrecked really hard and a fuel cell will look completely mangled but it will still hold the fuel and it won't spill out which as you know fire is terrible in that kind of situation if you get in a wreck and you have to get out of the car quickly but you've just rolled your car over or something and maybe you're unconscious and your car's on fire that's bad news we are definitely putting fuel cell in this thing I need to find the best location for an 8 to 10 gallon self that's all the fuel that we'll need for this car that's the next big step basically in moving forward with this project all right so since uh Damon has blocked the shop door with a Hummer we're going to take the Hummer since we have to move it anyway to be able to close the door so it was an easy decision all right let's see if this start works good to go foreign oh yeah Eric you ready oh we got the safety lights going we're going to d-sport just follow us BMW power let's get the lights Eric let's get the lights going through the whoops look in the mirror Mike there's a dip wait Mike there's a gym America what happened to Eric why is he so far away what do you do slow now for that dip I don't know why you might does not have 33 inch tires on his BMW so we're almost at d-sport and well I'm hoping for good news because he just said that he had an update for me but he didn't really go into detail with uh what was going on I'm really hoping that there isn't anything wrong with any of the parts that's going to set us back even farther like we already know that the crank was slightly bent and that's going to have to get repaired but we still haven't found out about the cylinders if they're reusable how thick they are if we can Source other cylinders see if they can machine something else down to fit in the stock location and maybe go a little bit smaller on the bore and go with a smaller piston there's just a lot of details they're figuring out for us we are at d-sport we're gonna check on the Block and the heads hey what's happening how's it going good good how you doing good good good to see you good to see you too so yeah I have a little bit of news for you one of the heads right now is in the CNC we've got the block here uh with one of the sleeves got out of it oh cool I could tell you what we had to do to kind of get there and then over here we've got the cylinder head this is where I think we're going to spend the majority of our time we're getting this thing ready you guys done a lot of work to it already trying to get all of that build up out of the exhaust Port usually direct injection engines are notorious for intake valve deposits these intake valves weren't bad at all but it had a bunch of junk on the exhaust side yeah so it was pretty built up in there yeah and it's like almost like corroding and fusing itself to it so we determined the only way to do it would to be fully polish the exhaust port a lot of what we have to do is literally by hand with strips of different sandpaper of different grits and kind of going through by hand and then using a Dremel and stuff to work through it so yeah we're gonna have a few hours in these says to get them to get them all cleaned up but they look like I mean it's like a mirror yeah it's gonna get even better than that but yeah we want it so that that carbon has no place to stick yeah so the smoother you make it there's there's really nothing for it to stick to and I think with some of the design changes we're going to do on the Piston I think that's going to help us get some better oil control in here yeah and alleviate oil and stuff that must been coming up through those Rings getting in this combustion chamber and getting stuck in the exhaust Port yeah I think actually Tim has the Rings Tim oh sorry so I've never seen an engine with this with this thing except for a Porsche Motorsport race engine it was a two ring motor this is pretty wild that it's in a street car and oh and it's still a three piece I've never seen a three-piece oil control ring that's this thin I think what did we say it was like a millimeter and a half yeah one and a half millimeter like stacked together it's a crazy thing because that's usually the thickness of like the middle range yeah normally on an oil control ring package they're about anywhere from three millimeters 2.8 2.5 that's your common one and then a really thin one is usually a two piece and it'll be a two millimeter yeah but to get a three piece and one I've never seen anything like that the lighter your rings the less inertia they're going to have when they're going at super high RPM so they're not going to flutter they're going to stay where they want to be yeah and and let's get the direction as well right yeah less friction as well and it also helps to get that seal in the bore if the bore is not perfectly round and stuff it is it's a little bit more conforming that that makes sense yeah we don't really need this thin of a ring yeah you know Ferrari they did an excellent job of engineering they used pretty much every trick in the book as I pulled this apart to get as much horsepower out of the as they could out of this you know normal aspirated yeah exactly I mean that is very very impressive just the way they transition from the port into the two valves it is so smooth those ports are crazy and the chambers in the head everything is like Top Notch Mike I'm going to give you a few of our secrets here okay all right cool these don't look like the most sturdy clamps out there yeah but in fact when you're holding a work piece you'd never want to put too much stress in it oh you just want to put the right amount of stress in there and if you can figure out a way to cut it and machine it or do whatever you're doing where you're not inducing a lot of stress yeah you're not going to deform this as much exactly I did some crazy clamps you could actually warp it you machine it and then you take it out and it's worked the other way right so it goes back yeah so we use these little you know woodworking clamps yeah um to do that now once we have it on here you'll see we have a fourth axis in here so that allows us to rotate rotate 360 Degrees we already got everything leveled out but once we do we put it on here and you never know exactly how well the manufacturer did in in matching the flatness of this surface yes they should be parallel yep and on the first head that we cut it was under a thousands of an inch in variants wow so it was it was pretty good this one had a little bit more from this side to this side we can go through we have this actual probe here and with this probe we can go to any location the probe will sense a touch in any direction so if you if it goes from the bottom see how the light turns green yeah or left or right anytime you you hit this it's going to tell the computer hey so we have time to touch off and then yeah exactly so we can go down here touch right there just get it barely touched it's just look at the light now just to where the light turns off exactly so we could zero that out there so now our our Z there is zero yeah and now we can move it and bring it to the other side of the head and touch off here and see how much difference we have okay so now we touch here and you see we're at zero again yeah so we were able to use that fourth axis to line up the head perfectly this way so now we're flat across here now unfortunately there's a little bit of variance in this head so as we go across this way what we want to see as we go here we want to see another zero yeah nine tenths of a thousandths ninety percent of the thousands yeah not too bad at all we're gonna make it perfect we're gonna switch tools out here will switch the tool out so now that's a nice fly cutter yeah that's all it is a big fancy fly cutter with a lot of Mass to it you have a lot of mass you have a lot less chance you're going to get any type of weird vibration or anything yeah in the tooling and stuff so we can use different types of cutters here everything from Sarah metallics to regular carbide CBN which is a cubic boron nitride which is the second hardest material to a diamond and PCD which is polycrystalline Diamond that's the hardest one out there and that's actually what we have in here so this is going to be a diamond cut on here and I'll leave it light a really nice almost like a rainbow finish on it we'll first just line up our y so our Y is the is the center of it this way so now we're zeroed on the Y so now we just gotta tell the machine exactly how far away this is from here we can just lower this and when it gets zero here oh you know that distance already that is this is exactly three inches so now we just tell the CNC hey our tool is three inches away from the surface we want to cut yeah so now it does so that's it so now we're set up Max we were a foul low on that side so we're gonna cut just a foul and a half we should touch everything yeah unless there's a little dip or something in there make sure we're not hitting anything we're not hitting anything we can go ahead and start that up so that's spinning at 2000 RPM we tell it what direction we want it to move 40 inches in the X Direction and we're going to tell it to beat at six inches per minute so you can see it's snowing in here now yeah it is that's That's how little little yeah it's an aluminum snowstorm right now it's like little tiny curls doors closed on your own CNC machine we're only leaving it open here because we're trained professional and we want to get you good shots too foreign we have a little bit more to cut but that's okay because we're gonna it's gonna go back in here and get the same service again after we do final valve job after all the polishing the ports all that's done it's going to come in here and get a final one and then depending on how that comes out sometimes we'll even do a hand lap on top of it so that would just be to get every single little one of those lines out right so you got a perfectly flat surface like the ra of this is probably I don't know five or six or something yeah once we do that if we hand wrap it we can get down like one or two it's like nothing yeah that's crazy that was uh really cool to see thank you so much for sure no problem no problem yeah I hope the hopefully we'll have some news for you the next thing we're going to be doing is redressing all the valves get them all up to spec and stuff and they look good they all look sleepable which is good because there's 48 of them yeah in this engine so we want to save them yeah exactly no they look good I think we can get that all going yeah we're gonna order the material to make the plates that are going to let us do the valve job and the place that's going to let us do the honing on the cylinder I'm glad that we can reuse those cylinders because that saves a bunch of time bunch of time money yes the Unicorn SEMA car it has to actually run well that's the idea that's the whole deal that's the idea any chance that we can get it on the dyno uh absolutely okay good yes good all right yeah that uh I mean the Dino's right here yeah yeah all the engine work is getting done here it only makes sense that we're gonna run it I mean it's Gotta sound twice as good as one of your BMW or one of my Nissan engines you know being a V12 exactly that's all I'm thinking I mean the cool thing about this engine is it's so much just like an inline six yeah I mean just doubled up it's doubled up yeah so we don't have to think too too differently about it so yeah yeah it's just you're doing twice as much work on the heads right now exactly it's not so bad cool deal well thank you thank you appreciate it see you soon all right see you soon thank you awesome visit to d-sport and a lot of good news so we're going to be able to reuse these cylinders which was a big concern the money obviously is an issue but the biggest thing is time we don't have a lot of time to get this build done and Damon wants this thing running and driving at SEMA we have 61 days left Pistons that are getting made that's going to take about four weeks so that's like 30 days right there we have rods that they said might take eight weeks well that's not gonna work we're gonna have to try to get them to speed up that process if possible I know that CP karilla already has their machines running 24 hours a day so I don't know how they're going to do it but I'm just gonna cross my fingers right now and hope that they can make us 12 awesome gorilla rods in time to get this thing all assembled put it in the car tune it and then get it to Sema it's a long road ahead of us not a lot of time complete your insta 360 car set now click the link in the description to get an exclusive offer just for DDE fans 25 off the 1rs a free selfie stick or a lens guard a free 128 gigabyte SD card for the first 50 buyers foreignDDE fam welcome back what's up guys we're back again what's going on Mike d-sport has some news for us so we've got good news um I don't know yet they said that they checked a bunch of stuff they measured everything out and they want us to go over there to get an update and I hope that it's good news we have 61 days left in telsema an insanely short amount of time oh geez so oh oh no no I want to love catboy so like I said we've got 61 days left Damon's in town now means that uh we're gonna be a little distracted here but we have a lot more work to do on the car before we go over to d-sport today we're gonna get cranking on that and uh we got to fix some stuff that Damon broke yesterday when he jumped in the car for the seat fit that tube is uh no longer packed in place remember when I said that this pedal is so much better than the factory throttle pedal well it is it's a lot stronger but it doesn't fit in this chassis like basically resting against it so even if we chopped all this out we still wouldn't have very much travel so we're gonna use the stock pedal after all stock pedal goes back in and it's a nice little mounting position and now we can shift everything back move it over a touch to do that we're actually going to cut this tube out unbolt the pedal assembly and make another flat plate here with some slots that will move further back so we can position everything test fit it make sure we like it and then we can figure out how to do the final mounting we move on with a roll cage fabrication on a very high horsepower car you don't want to have three quarters of an inch of pedal travel where it's zero throttle and 100 throttle makes the car so hard to drive so you actually want a throttle pedal that has some travel to it we're gonna throw the stock pedal back in there make everything fit a little bit better so we redesigned that plate we'll cut this new one out on the plasma table tack it into the car again let Damon sit in the car again later on and then we can move forward so we got the pedal assembly bolted onto our new plate here that has the hole slotted about 40 millimeters further back we're also shifting it slightly closer to the throttle pedal since we have more clearance there with a factory pedal than we did with the Tilt and pedal so able to get this the pedals lined up actually even better a little better for heel toe foreign back in the car with the factory throttle pedal I'm actually kind of tippy-toe right now so if I was going to push the brakes my leg is completely extended flat which is a good thing being that we are in the seating position for Damon he has longer legs than I do so he will have a little bit of Bend at his knees that'll be perfect when I move the seat forward into my position probably right around here oh there's the cap the Damon shot off yesterday when he stopped on the brakes with nothing connected there's a little dust cap on the master cylinders to stop stuff from getting in there so the factory throttle pedal feels okay it is a bit soft throw on this is okay so we have a decent amount of travel with the tunnel and the throttle pedal positioning is actually pretty good so three quarters over on my foot throttle pedals down side of my foot is right near the side of the firewall yeah this looks good I think the only thing we have to check now that we moved the pedals over closer to the center the steering column you might have an issue on the other side looks like from the center of my driving position it will go right past the brake pedal which should work out that's going to work I'm just going to double check the other side of the firewall to make sure there's nothing that's going to obstruct us there but I think we can get a steering column in here right next to the side of the brake pedal will fall right there I feel like the steering is really centered up which is nice some cars you have to put the steering wheel offset a bit and it feels weird when you're driving it other cars actually tilt the steering column at an angle and that also feels weird because your driving position and where the steering wheel is sideways one way or the other so it just has kind of an odd feeling in the car the old school cobras are like that you actually sit super sideways in the car actually this way because the trans tunnel is so big and the inside of the car is so weird but the steering wheel is pointing one way and the pedals are pointing another way and you're kind of like crossed up in the car it's a really interesting car to drive I think we'll probably shift the brake pedal over since it's adjustable we can actually move these bolts over to the side a little bit and shift the pad over so this is a little closer this is a bit of a reach there you can do like a big twist over but I like to do more of the Roll the style heel toe that'll give us a little more room on the clutch pedal as well so your feet aren't touching in between here and overall I'm liking it this feels good as far as positioning goes the steering wheel to shifter this is looking pretty good I think this is right about where the shifter is going to sit we may have to cut this out a little more that is not a big deal this will go right around there steering wheel nice and centered up and then we have a good amount of room here to put our e-brake in e-brakes I like to have a little bit more forward so the transition between the steering to the shifter doesn't get basically interrupted by that right in the middle it also gives you a little better leverage if you're too hunched back here you don't really have you know good pull a good feel so having it kind of extended arm almost to grab and pull it's pretty ideal and I think that actually is going to work out really well we have a good amount of room in between the shifter and the steering wheel it's gonna work it's gonna work really good you excited Tim I'm excited mark and dealing with this F12 build ordering all the parts not having any money you know what I just need to take a break it's time to place a video games oh yeah all right so most of you guys are already familiar with the insta 360 X3 camera but they just came out with this brand new three suction cup vehicle mounting system and it makes putting your insta 360 onto your car your truck whatever it is so easy and it's stable this is a one-person setup it literally sets up in a minute and you're good to go this X3 is brand new half inch sensor captures the action in Vivid 5.7 K 360. choose your favorite angle after the fact with easy reframing tools in the AI powered insta 360 app all right so we had it on the back of the car now we're gonna put it on the front of the car and just get a completely different perspective a bit of a unicorn shot the insta360 triple suction cup car mount provides a unique third-person perspective when filming your ride an all-new revised design provides a solid sturdy mount for your X3 ensuring your car content looks seriously Next Level while guaranteeing a safe and stable support for your camera it's the 360 X3 camera paired with their brand new triple suction cup vehicle mounting system it's an absolute Game Changer complete your insta 360 car set now with the newly released multi-functional durable branded suction cup combined convenience and quality purchase your insta 360 camera and essential accessories in one easy step click the link in the description to get an exclusive offer just for DDE fans 25 off the 1rs a free selfie stick or a lens guard a free 128 gigabyte SD card for the first 50 buyers don't miss out on this exclusive deal just for the DDE audience yo but what time is it oh oh man all right so now that I'm happy with the pedal box location we've decided to go with a factory pedal we can move on to some other roll cage Fab and the next tube that I want to do is the header so this is a very important tube because it ties these two bars together without this tube across here if the car did roll over this tube could fold in very easily it wouldn't have a lot of strength so it could just basically Crush down fold in that's not the idea of a roll cage you want to tie this in but we also want to make sure we get it up as high as possible even though it is a bit further than where the driver is sitting there is a chance that the driver's head or passenger's head could make contact with that bar so we're going to try to put it in this little Groove here just like we did with the a-pillars on the side it's on a weird Bend it's next to two band it's going up and it's going to be rotated about 45 degrees that way so I'm going to make it out of some thin wall cheap tubing first cut and Tack together just like we did with the template for the a-pillars measured across here it's about 43 inches I'll mark that out on a tube cut that and then I have a piece of scrap here that had a 17 degree Bend in it it actually looks like it fits pretty good so I'm going to try this first but keep a longer piece of tubing on it and then see if I can get it right the first time so I'm just going to remake this I've got 43 inches across and that's giving myself probably about an inch and a half extra on each side so we'll cut that at 43 and then we'll chop the tube in half that way I can basically mirror it and do both bends both notches just keep trimming down that Center to get the tube to be the exact right length then I can get the measurements off of that and make it properly the first time with the correct piece of tubing the reason that I'm using this tube it's thin wall tubing it's very easy to work with it cuts quick it bends quick it's also it's very cheap so this is about I think it's less than two dollars a foot where the other stuff is four times that much this is just the more economical and easier way to go to mock everything I'll start chopping this up Notch it bend it fit in the car see how we're looking all right so we got our tube marked out where it's going to get bent and where the notch lands this is measured exactly I've got basically a punch Mark where the hole saw is going to go and then I have the Scribe line this way for the Bender so it rotates right and the start of the bend now that I have all this measured out when I make the other part the correct one it will be exact I'm just going to confirm that the notch is correct and yep that looks good so I can put in the Bender now bend it 17 degrees on this Mark do the same on the other side pop it in there and then all I have to do is basically trim this down get it the correct length end to end tack it together and we will be good to go to make this out of the correct roll cage tubing so I just pulled it out of the bender and I just want to confirm that the bend looks the same on both of these because this one was really hard to measure the bend couldn't get an accurate measure off the back of the tube because it was smashed this I couldn't tell if it was really at the end of the bend or if this was cut properly then I'll put this piece inside the car make sure it looks good there and then I'll bend the other side all right let's see if this thing fits see that looks pretty good all right I will bend the other side up match this one so now that we got both tubes bent and notched measured the roof to find the center of the car marked that I marked each tube at the center we're gonna pop those in now if it all fits well we'll tack it together and we can make the correct piece all almost spot on there I think it might need to come back a little more which means it needs to get a little shorter yeah I don't know actually that's pretty much it pretty good I think it just like the middle yeah it might take like a millimeter off maybe two millimeters off but the notch fits really good everything looks really good I think I might just sand this down a little bit it should be good to go now that we have both these tubes trimmed up I took just a little bit more off of there probably about one to two millimeters as a pillars come up we were just a little too far forward so we'll get that Twisted back a touch and we're good to go we're gonna attack it in place it's one of the other tubes that finishes off the main the basic structure of the cage so it'll be good to get this out of the way then we just have door bars left down tubes harness bar diagonal a couple tubes here and there we're almost done right all right see the fits uh it looks pretty good it is nice and tight so it's falling forward because the a-pillars move out but when it's in the right spot I think it looks pretty good all right so the test tube fit perfectly now we can cut it out of the proper tubing mark it out get all of our bends in it notches everything ready put it in the notcher cut those notches bend it up put it in the car tack it in place and then we can go over to d-sport and check in on what's going on inside of our engines not straight anymore I missed I completely missed the no look fast I know like it did not work for me this time I missed it by an eighth of an inch my turn come on all right first try first first second try I got it that time boom first time all right that looks really good I'm happy with that we are moving along with this project 61 days left and we have a half a roll cage and a pedal assembly I'm not even working on this car and I'm stressed out now that we have our header bar done and tacked in place huddle assembly mocked up in the correct position now now I can move on with finishing up these boxes so they're going to get shortened a bit so we have less intrusion basically into the driver department for driver passenger ankles and all that shorten that up finish that plate still have to make door bars but that's going to be I might even run tubes through the front firewall to the shock Towers but I want to wait until we have the engine in before I do any of that stuff we may add gussets there's a lot of other stuff that we can do but the main parts that we need to finish are the diagonal bar which goes from the passenger side uh bottom of the main hoop up to above the driver's head and then harness bar we've got the two down tubes that are coming off of the main hoop basically to the rear shock Tower area even though this isn't a McPherson strut car so it doesn't really have a shock Tower per se but that's a strong point where we're going to land it that's all stuff that we have to do but the first thing that I need to figure out is fuel system placement fuel cell we need to find a good location for that measure the amount of space that we have order one hopefully that's off the shelf and hopefully that's already Complete because if it's a custom fuel cell or one that's not in stock it usually tends to take about six weeks that would not work well with our timeline here's the factory fuel cell that we took out of the F12 so it's actually a very nice piece it's all aluminum fits in the chassis really well but now that we've added the Quick Change diff we had a problem with contact with the bottom of this area here it's also I think this thing holds 24 25 gallons something like that it is a lot of fuel and we do not need that much fuel for this car so an option is to cut this thing down basically chop it and use a section of it but the main problem with this tank is that it is not made for a race car so it doesn't have baffles inside it doesn't have a surge tank which means something that is holding the fuel and not sloshing around also inside of a fuel cell there's foam it's a an open cell foam that slows the fuel down from sloshing side to side so it keeps the fuel pretty level on the tank and you can run it down fairly low where a lot of cars from the factory once you get below a half tank or maybe even three quarters of a tank and you're on track and all the G loads are basically making the fuel slosh side to side you're going through the s's you're on the brakes you're on the throttle and that fuel is basically just sloshing around everywhere in there and that could be a huge huge disaster especially on an engine like this twin turbo V12 1500 horsepower there is no room for air in the tuning and if the fuel was sloshing around and the fuel pumps picked up Air instead of fuel and pumped that in the injectors would basically fire half fuel half air it would run lean and we could melt a piston it could detonate and spin a rod bearing and could throw a rod it could crack a block crack a sleeve the biggest and most important reason that we're putting fuel cell in is for the baffling system and for the safety of that fuel cell so this tank is just a layer of aluminum it can get punctured and basically split open and spill all the fuel out the fuel cell is shell and aluminum shell and then inside of that shell is a bladder made out of a special material sometimes it's almost like a Kevlar type material if it gets punctured on the outside that shell on the inside collapses twists and it is very puncture resistant so most likely you can have a car that's wrecked really hard and a fuel cell will look completely mangled but it will still hold the fuel and it won't spill out which as you know fire is terrible in that kind of situation if you get in a wreck and you have to get out of the car quickly but you've just rolled your car over or something and maybe you're unconscious and your car's on fire that's bad news we are definitely putting fuel cell in this thing I need to find the best location for an 8 to 10 gallon self that's all the fuel that we'll need for this car that's the next big step basically in moving forward with this project all right so since uh Damon has blocked the shop door with a Hummer we're going to take the Hummer since we have to move it anyway to be able to close the door so it was an easy decision all right let's see if this start works good to go foreign oh yeah Eric you ready oh we got the safety lights going we're going to d-sport just follow us BMW power let's get the lights Eric let's get the lights going through the whoops look in the mirror Mike there's a dip wait Mike there's a gym America what happened to Eric why is he so far away what do you do slow now for that dip I don't know why you might does not have 33 inch tires on his BMW so we're almost at d-sport and well I'm hoping for good news because he just said that he had an update for me but he didn't really go into detail with uh what was going on I'm really hoping that there isn't anything wrong with any of the parts that's going to set us back even farther like we already know that the crank was slightly bent and that's going to have to get repaired but we still haven't found out about the cylinders if they're reusable how thick they are if we can Source other cylinders see if they can machine something else down to fit in the stock location and maybe go a little bit smaller on the bore and go with a smaller piston there's just a lot of details they're figuring out for us we are at d-sport we're gonna check on the Block and the heads hey what's happening how's it going good good how you doing good good good to see you good to see you too so yeah I have a little bit of news for you one of the heads right now is in the CNC we've got the block here uh with one of the sleeves got out of it oh cool I could tell you what we had to do to kind of get there and then over here we've got the cylinder head this is where I think we're going to spend the majority of our time we're getting this thing ready you guys done a lot of work to it already trying to get all of that build up out of the exhaust Port usually direct injection engines are notorious for intake valve deposits these intake valves weren't bad at all but it had a bunch of junk on the exhaust side yeah so it was pretty built up in there yeah and it's like almost like corroding and fusing itself to it so we determined the only way to do it would to be fully polish the exhaust port a lot of what we have to do is literally by hand with strips of different sandpaper of different grits and kind of going through by hand and then using a Dremel and stuff to work through it so yeah we're gonna have a few hours in these says to get them to get them all cleaned up but they look like I mean it's like a mirror yeah it's gonna get even better than that but yeah we want it so that that carbon has no place to stick yeah so the smoother you make it there's there's really nothing for it to stick to and I think with some of the design changes we're going to do on the Piston I think that's going to help us get some better oil control in here yeah and alleviate oil and stuff that must been coming up through those Rings getting in this combustion chamber and getting stuck in the exhaust Port yeah I think actually Tim has the Rings Tim oh sorry so I've never seen an engine with this with this thing except for a Porsche Motorsport race engine it was a two ring motor this is pretty wild that it's in a street car and oh and it's still a three piece I've never seen a three-piece oil control ring that's this thin I think what did we say it was like a millimeter and a half yeah one and a half millimeter like stacked together it's a crazy thing because that's usually the thickness of like the middle range yeah normally on an oil control ring package they're about anywhere from three millimeters 2.8 2.5 that's your common one and then a really thin one is usually a two piece and it'll be a two millimeter yeah but to get a three piece and one I've never seen anything like that the lighter your rings the less inertia they're going to have when they're going at super high RPM so they're not going to flutter they're going to stay where they want to be yeah and and let's get the direction as well right yeah less friction as well and it also helps to get that seal in the bore if the bore is not perfectly round and stuff it is it's a little bit more conforming that that makes sense yeah we don't really need this thin of a ring yeah you know Ferrari they did an excellent job of engineering they used pretty much every trick in the book as I pulled this apart to get as much horsepower out of the as they could out of this you know normal aspirated yeah exactly I mean that is very very impressive just the way they transition from the port into the two valves it is so smooth those ports are crazy and the chambers in the head everything is like Top Notch Mike I'm going to give you a few of our secrets here okay all right cool these don't look like the most sturdy clamps out there yeah but in fact when you're holding a work piece you'd never want to put too much stress in it oh you just want to put the right amount of stress in there and if you can figure out a way to cut it and machine it or do whatever you're doing where you're not inducing a lot of stress yeah you're not going to deform this as much exactly I did some crazy clamps you could actually warp it you machine it and then you take it out and it's worked the other way right so it goes back yeah so we use these little you know woodworking clamps yeah um to do that now once we have it on here you'll see we have a fourth axis in here so that allows us to rotate rotate 360 Degrees we already got everything leveled out but once we do we put it on here and you never know exactly how well the manufacturer did in in matching the flatness of this surface yes they should be parallel yep and on the first head that we cut it was under a thousands of an inch in variants wow so it was it was pretty good this one had a little bit more from this side to this side we can go through we have this actual probe here and with this probe we can go to any location the probe will sense a touch in any direction so if you if it goes from the bottom see how the light turns green yeah or left or right anytime you you hit this it's going to tell the computer hey so we have time to touch off and then yeah exactly so we can go down here touch right there just get it barely touched it's just look at the light now just to where the light turns off exactly so we could zero that out there so now our our Z there is zero yeah and now we can move it and bring it to the other side of the head and touch off here and see how much difference we have okay so now we touch here and you see we're at zero again yeah so we were able to use that fourth axis to line up the head perfectly this way so now we're flat across here now unfortunately there's a little bit of variance in this head so as we go across this way what we want to see as we go here we want to see another zero yeah nine tenths of a thousandths ninety percent of the thousands yeah not too bad at all we're gonna make it perfect we're gonna switch tools out here will switch the tool out so now that's a nice fly cutter yeah that's all it is a big fancy fly cutter with a lot of Mass to it you have a lot of mass you have a lot less chance you're going to get any type of weird vibration or anything yeah in the tooling and stuff so we can use different types of cutters here everything from Sarah metallics to regular carbide CBN which is a cubic boron nitride which is the second hardest material to a diamond and PCD which is polycrystalline Diamond that's the hardest one out there and that's actually what we have in here so this is going to be a diamond cut on here and I'll leave it light a really nice almost like a rainbow finish on it we'll first just line up our y so our Y is the is the center of it this way so now we're zeroed on the Y so now we just gotta tell the machine exactly how far away this is from here we can just lower this and when it gets zero here oh you know that distance already that is this is exactly three inches so now we just tell the CNC hey our tool is three inches away from the surface we want to cut yeah so now it does so that's it so now we're set up Max we were a foul low on that side so we're gonna cut just a foul and a half we should touch everything yeah unless there's a little dip or something in there make sure we're not hitting anything we're not hitting anything we can go ahead and start that up so that's spinning at 2000 RPM we tell it what direction we want it to move 40 inches in the X Direction and we're going to tell it to beat at six inches per minute so you can see it's snowing in here now yeah it is that's That's how little little yeah it's an aluminum snowstorm right now it's like little tiny curls doors closed on your own CNC machine we're only leaving it open here because we're trained professional and we want to get you good shots too foreign we have a little bit more to cut but that's okay because we're gonna it's gonna go back in here and get the same service again after we do final valve job after all the polishing the ports all that's done it's going to come in here and get a final one and then depending on how that comes out sometimes we'll even do a hand lap on top of it so that would just be to get every single little one of those lines out right so you got a perfectly flat surface like the ra of this is probably I don't know five or six or something yeah once we do that if we hand wrap it we can get down like one or two it's like nothing yeah that's crazy that was uh really cool to see thank you so much for sure no problem no problem yeah I hope the hopefully we'll have some news for you the next thing we're going to be doing is redressing all the valves get them all up to spec and stuff and they look good they all look sleepable which is good because there's 48 of them yeah in this engine so we want to save them yeah exactly no they look good I think we can get that all going yeah we're gonna order the material to make the plates that are going to let us do the valve job and the place that's going to let us do the honing on the cylinder I'm glad that we can reuse those cylinders because that saves a bunch of time bunch of time money yes the Unicorn SEMA car it has to actually run well that's the idea that's the whole deal that's the idea any chance that we can get it on the dyno uh absolutely okay good yes good all right yeah that uh I mean the Dino's right here yeah yeah all the engine work is getting done here it only makes sense that we're gonna run it I mean it's Gotta sound twice as good as one of your BMW or one of my Nissan engines you know being a V12 exactly that's all I'm thinking I mean the cool thing about this engine is it's so much just like an inline six yeah I mean just doubled up it's doubled up yeah so we don't have to think too too differently about it so yeah yeah it's just you're doing twice as much work on the heads right now exactly it's not so bad cool deal well thank you thank you appreciate it see you soon all right see you soon thank you awesome visit to d-sport and a lot of good news so we're going to be able to reuse these cylinders which was a big concern the money obviously is an issue but the biggest thing is time we don't have a lot of time to get this build done and Damon wants this thing running and driving at SEMA we have 61 days left Pistons that are getting made that's going to take about four weeks so that's like 30 days right there we have rods that they said might take eight weeks well that's not gonna work we're gonna have to try to get them to speed up that process if possible I know that CP karilla already has their machines running 24 hours a day so I don't know how they're going to do it but I'm just gonna cross my fingers right now and hope that they can make us 12 awesome gorilla rods in time to get this thing all assembled put it in the car tune it and then get it to Sema it's a long road ahead of us not a lot of time complete your insta 360 car set now click the link in the description to get an exclusive offer just for DDE fans 25 off the 1rs a free selfie stick or a lens guard a free 128 gigabyte SD card for the first 50 buyers foreign\n"