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June 2012

Jun 29, 2012

86 Clutch development

We are making some progress with the 86 clutch development scissors

Mr. RS has taken down its transmission to locate an OE clutch kit:

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Here's the OE clutch, and it is like a new... well, it is new.sweat02

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Here's the housing, and still very clean as well.shine

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Although our FT86 is from Toyota, its drive-train parts remind us of Subaru vehicles.

Anyhow, now that the transmission is out of the way, it's time for Clutch-wizard to work his magic. thunder

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First step is to remove the clutch cover:

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Then to remove the flywheel:

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The current trend for a clutch assy. is to use a dual-mass flywheel and a light-weight disk set...

However, FT86 OE clutch assy. uses a single-mass flywheel and a spring dampened disk set. 

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When we removed the flywheel, we found this metal plate placed between the flywheel and the crank. eye

With further inspection, we also found a sensor (position/speed sensor?) attached to it.

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We normally see the sensor attached to a flywheel itself, but this separate sensor will make the development a bit easier since we don't need to do anything special to our flywheel besides making it lighe-weight.

Big-boss himself was also at the scene to help out the development:

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It is nice to work on a brand new car since the car is so clean and no rusty parts to deal with. bleah

We found Clutch-wizard was having a staring contest with the OE clutch... coldsweats02

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Time to do some measurements.

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While the car was up on the lift, we have installed a suspension kit from ENDLESS. good

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We cannot wait to see how the new suspension set-up will work with our LSD.

But for now, we have to wait till the clutch development is complete... we cannot drive the car without the clutch and transmission in place. shock

Jun 19, 2012

Test for 86 LSD

Mr. RS and Tommy had a chance to take our OS Giken LSD equipped 86 to a much bigger circuit for a LSD test.

This time around, they have booked a spot at Okayama international circuit famous for Super GT championship race. good

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They went on a week day, so when they got to the circuit, it was just them like a renting a whole track to themselves. happy01

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Right until they were ready to go for a spin that is...sweat01

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One after another started to show up, and they all were from out side of our prefecture and equipped for some sort of product testing.  Well, kinda' like us but in much larger scale with pit crews and digital equipments. wobbly

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The LSD test went well... but the stock tires and suspension setup leaved much to be desired for the track use. think

For the next test with our clutch kit, we will try replace the stock parts with aftermarket parts for better result.

Jun 18, 2012

Strange Clutch Kit

One day, our image character Izmon the R2D2 + Doraemon hybrid was wondering around the facility.foot

He has spotted our warehouse / shipping manager T-shima laser printing a single clutch cover.
T-shima normally does it in a bulk, so knew something special about this clutch...eye

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Just as Izmon suspected, it was a special order clutch sign01

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Here's a housing + flywheel combo for the clutch.

Can you guess which vehicle this clutch is for?

If you guessed it correctly, then you should work for a clutch manufacturer.dollar

He had no idea what is it for...

It has such an unusual shape, and check out its back side:

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He have asked Clutch-master Y for more details about this clutch and he showed us the OE clutch:

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The OE clutch was attached to a ring-gear with pillars.

So Mr. Y has designed our clutch to fit the ring-gear as well.

BTW, the clutch he has built for this special order was R3A.

While he was obtaining as much information as possible from Mr. Y, Izmon was somehow forced to assemble it...shock

Izmon used to assemble clutch kits, so he had to recall the old days.

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He was able to assembled it, and here's the finished product:

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Here comes Mr. Y's professional inspection:coldsweats01

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Mr. Y told Izmon he did a fine job, but Izmon witnessed Mr. Y secretly reassembling it later...sweat01

Now it is time to reveal the vehicle name happy02

This clutch was for ...Jaguar XJ220shine

Jun 13, 2012

Time to dissect

We spent enough time at Nakayama circuit to understand how the stock 86 performs.

So now is the time to give it a special OS Giken made weapon to fight for the winning run sign01

Super Lock L.S.D.shine

First, we need to remove its differential carrier.

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Removing the diff. carrier was pretty easy, and look how clean this thing is...

It made us hesitate to get dirty.sweat01

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Anyhow, let's install the Super Lock LSD. wink

Here's Toyota OE Torsen type differential:

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Here's a familiar sight after installing Super Lock LSD: good

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We are planning to test the LSD ourselves at a race track soon. car dash
GReddy has tested it at the famous Laguna Seca for us already and it performed exactly as we hoped.
Now we just want to see and feel it ourselves.
We will report back here once we had a chance to go out to a circuit again. secret

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While the 86 was up on the lift, we noticed a shadowy figure underneath the car...shadow

The shadowy figure was Mr. Y.sweat02

He was looking at its drivetrain, and was thinking how to tackle the clutch.

Hurry Mr. Y, 'cause we are planning to launch the clutch kit in August.

BTW, Super Lock LSD for FT86 / GT86 / FR-S is now on sale. smile

Jun 12, 2012

New material for clutch kit

We have spotted Mr. Clutch-master Y unloading some mysterious materials at our warehouse. danger

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From far, it looked like some sort of gray plate,

But if you get closer...

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It has changed its color and now you see the familiar surface pattern.

You all know what it is right?

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Yes, it's a stack of carbon sheets.

We will cut out from these sheets to make the carbon clutch disks.

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They are lighter than they look.

We need to cut them through a special processing, and grind / polish them to make them useful for our parts.

Here's a sneak peek of the finished product:

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All new carbon clutch kit is currently in its final stage of development. new

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We are testing the clutch kits for models from Nissan, Lotus, and BMW.

Our race-spec Toyota Vitz/Yaris is also equipped with A-type carbon clutch kit for testing.

So far so good good

You might see them in our product line-up sooner than you thinkshine

Jun 11, 2012

Circuit test

Time to test our 86! ...and Vitz.sun

We wanted to see how a stock 86 performs before installing OS Giken performance parts.

Some may say to do a proper break-in procedure before going all out, but not our Big-boss.

He simply wants to test our parts ASAP...

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This wasn't a planned test (well, not this soon) so we weren't sure if we could find a place to test at the last minute.
Good thing we had an Ex Moto-racer in OS Giken who could book a place with a single phone call.telephone

Since we are going to a circuit, we have decided to bring Vitz for some circuit product testing for our LSD and clutch.

Let's see how our Carbon clutch performs on track.

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We have arrived at Nakayama circuit at last.

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Complete the registration process,

     and off we go to the track! run

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But WHAT THEannoy... it started to rain as we walked out side of the registration office rain

We were hoping we could test both vehicles in dry condition.  Who's a rain man here?pout

Anyhow, a little rain won't stop uspunch 

First, we'll test 86:

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We had our own time attack competition among ourselves, but unfortunately, we all did better in our Vitz. sweat02 

Keep in mind that our Vitz is modified for track use, and Nakayama circuit is a short track with many tight turns so naturally Vitz was better suited for the track.  Also, we couldn't turn off the VSC (vehicle stability control) on 86 for some reason.  We have followed the instruction on the user's manual, but it didn't completely deactivate the VSC.  Maybe there is a special technique to deactivate it completely like some of other Toyota vehicles...

Let us see how this will affect after installing our LSD.

Next up is the Vitz:

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Like we have mentioned, our Vitz is a race-ready spec even with a roll cage.  On top of that, it is equipped with Spec-X SuperLock LSD and the secret Carbon clutch kit.

This is a fun little car, and the Carbon clutch worked marvelously.shine
It has lighter pedal feel with easy clutch engagement/operation.

The SuperLock LSD also performed as expected from OS Giken. 
Open differential on the street, 100% lock on the track when you need them.
(100% lock capable on the street as well, but please drive safely)

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We will come back to the circuit once our 86 is equipped with OS Giken parts.

Cannot wait.smile

Jun 04, 2012

Cosmetic surgery

On day two of our 86 arrival, we have decided to give it a quick make up.wink

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We wanted something simple and subtle, so we have chosen Modellista body kits.
You can find them here at:http://www.modellista.co.jp/product/86/index.html

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Starting from a front bumper lip.

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It seems the installation of this kit is simple enough.

These bumper lips /side skirts are very subtle changes, but makes nice difference in its appearance.

BTW, the installation is done by Mr. RS during his break from OS-88 assembly...coldsweats01

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Starting from front, then move on to side, and finally rear.

Before:
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After:
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The body kits included a front bumper lip, side skirts and rear bumper lips.
After installing them all...

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Sooo, what do you think?

Tommy and Big-boss were discussing about the LSD while Mr. RS was working on the car.

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Don't forget to place our stickers, and we are good to go.
(Wait... but when did we install the LSD??)

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Well, a small detail aside, it was the first step for our 86 to becoming OSG-mobile bullettraindash

Jun 02, 2012

The newest member of OS Giken

Long-waited Toyota FT86 (Scion FR-S) is finally arrived to our office.scissors
BTW, the most dealers in Japan don't really carry any inventory for new cars.  Instead, they use built to order base system sort of like OS Giken... sweat02

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We don't have any plan or goal for its modification yet.
But one thing for sure that it will have OS Giken LSD and Clutch kit shortly.
Who knows, we might even go as far as to make close ratio gear kit for it.smile

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Don't you just love the new car smell?
Every part of the car is spotless and so clean that we felt uncomfortable touching it.coldsweats01

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We haven't had a time/chance to test drive it since we have orders to prepare for customers around the world.present

Please keep checking our weblog for future update of our 86/FR-S eye

Jun 01, 2012

Brand new clutch for Vitz/Yaris

Let us share some info on a special clutch we have installed in our Vitz/Yaris.

Like I have mentioned before, our original plan was simply to test SuperLock LSD for Vitz/Yaris... but I guess Mr. RS asked Clutch-wizard at the last minute to make a new clutch while the transmission is removed.flair

We had no idea what type of clutch he was planning to make, but we knew he won't disappoint us.catface

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Here's the flywheel... well, it's a standard OS Giken flywheel and no light-weight version of any kind.
Don't worry, he won't disappoint us... we know he won't...sweat01

 
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Using a torque wrench to tighten the flywheel bolts with specified torque.

A word of advice:shine  when tightening the flywheel bolts, gradually tighten the bolts to reach specified torque instead of tighten them all at once.  Be patient.

Once the bolts are tightened correctly, it is time for a clutch disc...

 

 

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What the sign03

Isn't that a CARBON discsign02

We have been developing the carbon parts for many years, and now we finally found the right materials to meet our strict quality standard.  Soon you will be able to get your hands on our carbon clutch kits.

So stay tuned.good

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Anyhow, put the cover and we are finished.
Just look at the mysterious glow of the blue alumite cover...
It's a shame that we cannot look at it once the transmission is installed.weep