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Level Motorsport M86 Build - Rocco

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I don't know what this is, but it looked silly.<br /> <br /> Spray foam we use to fill dead space in panels that we are shaping for molding. -Rocco
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I don't know what this is, but it looked silly.

Spray foam we use to fill dead space in panels that we are shaping for molding. -Rocco

  • I don't know what this is, but it looked silly.<br /> <br /> Spray foam we use to fill dead space in panels that we are shaping for molding. -Rocco
  • A rear quarter window right out of the mold. We have been making tons of quarter windows testing different resins for weight and strength.
  • M 8 6 ?<br /> I was getting creative.
  • The way you test if you have done a good job or not is to apply paint on the gear, and spin it through the diff. If the gear it rubs against wears a consistent pattern in the paint, you've done a good job. You must test this in both directions- coast and drive.<br /> If the pattern isn't very consistent in the coast direction, it will usually break in over the course of driving. If the pattern isn't very consistent in the drive direction, it will just break.
  • A close up of the shims that separate the bearing and adjust the lash(don't quote me on that).
  • Untitled photo
  • The carbon fiber tail-light cap.
  • Mockup of the dash. CAD. Cardboard Assisted Design.
  • Here they are taken out of the diff. Adding 1/1000th of an inch can put you out of spec.
  • A similar process goes on with this bearing to set the preload.
  • A slightly thicker shim on this stack can mean adjustments throughout the rest of the diff.
  • The shims are very thin.
  • All of the pieces, once we got everything shimmed properly and to spec.
  • Now it was time to make things permanent- press the bearing!
  • A view of the suspension hanging from the shock tower.
  • Handy welding bucket.
  • Sweet coilovers!
  • Untitled photo
  • The underside of the car revealed many support structures, such as this one for the trans.
  • Untitled photo
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