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View Full Version : 2012 25 Hours of Thunderhill Recap Part 1



crash
12-24-2012, 01:37 PM
PROTOTYPE DEVELOPMENT GROUP
2012 25 HOURS OF THUNDERHILL

So the Fiscal Cliff is upon us, the Mayans are predicting the end of the world, and children are being slaughtered by mad men.
While an auto race may seem inconsequential in comparison to the realities of the current world around us, I have to tell you that, although our team did not finish as high in the rankings as we would have liked, I came away from this year’s 25 Hours of Thunderhill endurance automobile race with a huge grin on my face.

For some at this race it is all a business proposition. For others, it is simply a chance to get a ton of track time for a small amount of cost. For Team Prototype Development Group it is a rare opportunity to mix the two, bring in a big name driver like Elliot Forbes Robinson, and just have a GREAT TIME while trying to do well in the “longest endurance road race in North America”. Maybe forgetting the troubles of the world, if for just a couple days, factors into the draw to this event as well. Whatever it is, (and I am still not exactly sure why I do this every year) no matter where we finish, I find myself oddly at peace and with a smile on my face every year. For some things in life, it is not the destination as much as it is the journey that makes it a worthwhile endeavor. This race is one of those things.

Enough of this philosophical mumbo jumbo, let us get down to the racing!

This year’s 25 hour race adventure really started about 10 days after last year’s event ended. We had a very good showing last year and ended up 4th in class and 4th overall. This allowed us, as a team, to go out and drum up some needed sponsors and talented drivers to really transform our VERY low budget team into just a low budget team! We could not have made the showing we did this year, both at SEMA and at the 25 hour race, without the help of our sponsors. We are unbelievably thankful for their support. Companies like Mendeola Transaxles, Baja Designs lighting, Chase Chevrolet, Hoosier Tire, Factory Five Racing, Tel Tac data, Stop Tech Brakes, My Race Shop LLC, and especially all the volunteers that put this car together and made these events happen. People who love the GTM and send us what they can, which in some cases is $50, just to pitch in and help from their locations in Australia, Europe, and, of course from all over the U.S. It is because of the combined efforts of ALL these individuals and companies that we, Team PDG, are even able to compete in this race every year.

So for 2012 the car was completely redone. That was apparent to anyone that saw the car at SEMA this year. What may not have been apparent was that, largely in part to a couple of sponsors coming on late in the eleventh hour with products we simply couldn’t refuse to run on the car, we had basically no time to run the car as it would be raced. The fact is that while we had been running very good parts on the car all year long, there were just some things that weren’t available until right before this race.

For instance, we had been running a Mendeola transaxle in testing all year long. It was a great transaxle, but there were some improvements that the guys at Mendeola wanted us to try out for them. There were issues with some of the parts that Mendeola had gotten from other venders for our new gearboxes, and thus, what we had planned to test for ratios and shifting systems, among other things, many months earlier, were, in fact, going into the car for the first time Thursday…just before the morning test session…the day before qualifying.

Then there were the new, bigger brakes provided by Stop Tech, and the true slicks provided by Hoosier Racing Tires. None of these items had been tested until that Thursday morning. Yes we had done testing throughout the year. We tested engines, we tested wings, we tested shocks, we tested cooling systems, but quite frankly, we probably had just as many things on that car, come Thursday morning, that were completely untested, as we had new parts that got tested throughout the year of 2012. So to say that some very late nights and a ton of cell minutes were sacrificed in the last couple weeks leading up to that Thursday test would be putting it mildly. These race cars, no matter what level you race at, are a LOT of work. In most instances it is not a case of buying something off the shelf and bolting it on the car. Almost invariably there are issues with fitment that require custom modifications. Of course this leads to other pieces of the puzzle not fitting quite right and so what may appear to be a simple part upgrade install, can quickly turn into a full blown, fire up the milling machine, all night project.

End result? The Thursday test session was a complete and utter success! Just about everything went as planned, and that transaxle shifted as smooth as butter. We bettered our average times by about six seconds per lap and the overall fastest ever lap time was set for this car. Everything looked like roses on Thursday. But then again, it was only Thursday.

Friday practice and qualifying for The 25 Hours of Thunderhill is usually a pretty frantic time. People are really pushing things as far as last minute preparations and trying to get drivers that may be completely unfamiliar with the track some seat time, so it can be a treacherous thing to run a car in the Friday practice sessions. Matter of fact, the last two years they have had to bring in the helicopter to transport injured drivers out during the Thursday-Friday practice sessions. It is for these reasons that The Team usually does not practice on either Thursday or Friday immediately preceding this race. It is simply too dangerous. This year though, ended up being major incident free, and we went out for the evening practice session before qualifying. This is really where we started to see the effects of those late, last minute nights on the crew. We should have had the schedule posted, as we always do, on the pit cart so that we were sure when the evening practice session stopped and the qualifying session had begun. The last practice session is a little different in that there is no break between the practice session and the qualifying session. In other words, we go out and practice, but then the track is not cleared and the cars continue to run through the time at which the qualifying session begins. Unfortunately we were about 15 minutes off in our understanding of when qualifying would begin and as such set our fastest ever time in the car of a 1:51:45 with Steve Zadig at the wheel during what we THOUGHT was qualifying, but was actually still practice. That mistake took us from what would have been up near the front in the 2nd or 3rd row back to the 6th row in 11th position. Not what we had wanted or planned for, but also not so bad. It insured that we wouldn’t be back in the pack of trouble, should there be any, for the start of the race.

The start was exciting, as it always is, but largely uneventful. No major incidents, but certainly some “wanta be heroes” going into turn one. All was sorted out quickly though, and we settled into a 6th-7th position overall and then just let our natural advantages come into play.

In this race, anyone can bring anything they want to compete. If it doesn’t fit into a particular classification, or has not been previously classified under another sanctioning bodies rules, then it goes into ES class. Our class. On the other hand, if the vehicle does come to this race with it being classified under another sanctioning bodies particular class rules, then it must conform to those rules. So things like brake size limitations, or fuel tank size limitations largely restrict many of the cars that end up in ES, while we are not limited to those rules because our car runs under NASA Super Unlimited rules, which, pretty much means anything goes as long as the fuel tank is no bigger than 44 gallons and the proper safety equipment is present. So the end result is that we have a large fuel capacity, combined with the tires we choose that will allow us to go for hours at a time without a change, and, well, there you have it…natural advantages.

Plainly put, our strategy is simple…NEVER STOP! Or at least make as few stops as possible. Combine that with a team of drivers that are experienced, patient, and reasonably fast, and it should be a winning combination.

crash
12-24-2012, 01:38 PM
Part II

If there is one thing that is a constant about running a race that is basically the same as running two or more entire seasons of sprint races, nonstop, in a single 25 hour period, it is that there will be some sort of something that doesn’t go according to plan. There will likely be some sort of mechanical failure, even though you prepare for this race by basically coming to the track with a completely new car, and it is what you do in the face of adversity, like mechanical failures, that makes the difference between the winners and the losers during these grueling 25 hours.
I think this is one of the most powerful draws to this type of racing for me. It is not about a single decision that makes or breaks you. It is not about an axle bolt breaking, or brake pads and tires wearing faster than anticipated, it is, rather, about a cumulative effect of making the correct decisions over and over again to get to the desired goal. It is about hundreds, if not thousands, of judgments made “on the fly” with very little time to process the given information to come up with the right decision. It is about making the unthinkable failure a simple 1 minute fix because you have prepared with equipment and a thought process that allows you to get the job done better and faster than the other guy. THAT is what this type of racing is about. It is about thinking and problem solving. Simple as that, yet THAT is anything but simple.

So while we did have some minor incidents during the first half of the race, some spilled fuel-five minute penalty, passing under yellow-another five minute penalty, we went largely unscathed through the first half and our strategy was working superbly. We had worked our way up to 2nd in class and 3rd overall, and the race was “coming to us”, just as we had planned.

Then an hour and thirty five minutes into my two and a half our first stint, while under full load, coming onto the front straight, I heard that BANG! from the driveline that every driver dreads. An explosion in the drive train usually means, at the minimum, parts are heavily damaged and that the car will need to be towed in on a flat bed as the rear tires can frequently be locked up. If this type of failure does not cause the car to go flying off the track the driver is lucky. In my case, not only was it a huge piece of luck that the OUTSIDE axle was to blame, but because it broke coming onto the front straight, it was relatively easy to get back to the pits. If the inside axle had failed, it would have most likely resulted in the car turning VERY abruptly right into the front straight’s concrete wall at better than 90 miles per hour. Not something that would have been pretty for me or the car.
So we get the car pulled back to the garage, and it appears that the only issue was failure of the six bolts that hold the inner constant velocity joint to the transaxle output flange. A far cry, as far as repair time is concerned, from what it would have taken us to change out the entire gear box. We simply replaced the axle and bolts in about 20 minutes, and the car was good to go again. This time with one of our faster drivers, Steve Zadig, behind the wheel.

One of the things about these races which I have found I am very good at is that I seem to be able to control my adrenaline pretty well. While some drivers get very “hyped up” and then are unable to sleep in between their stints, I do not have this problem. I do my work in the driver’s seat, get out, debrief with the other drivers or with anyone who has any questions about the car, get myself something to eat and go in a motor home and fall asleep. Usually about 45 minutes before my next stint someone will wake me up, I get another something to eat, and I am good to go. Unfortunately, this wouldn’t be the case during this 25.

Steve was doing great. It was the middle of the night and he was turning his regular fast times. Then the crew noticed something happening. His times were getting slower. Steve finally radioed in that he didn’t feel well. Something was wrong. Our team owner Richard came and woke me up as I was the closest to the pits and told me I was going back in the car. I had been asleep for only about 45 minutes. Pretty much not what I wanted to hear, especially after Steve called in and said he had gotten sick to his stomach in the car! I know from being around my kids that the smell of barf pretty much makes me a sympathy barfer as well. This was NOT GOOD.

Long story short, Steve brings the car in, one of the crew cleans it up as best he can, and John Trefethen gets in there. He proceeded to turn excellent laps, and even with the two penalties, the broken axle bolts situation, and a lengthy stop due to a sick driver, we were still in the hunt, only dropping down to 7th place out of 13 starters in our class.

John did a fine job, as did David Ray after him, and after my uneventful sunrise stint, we had worked our way back up to 4th place. This was truly the verification that our team was the right combination of speed, talent, and strategy. We were looking like we were going to finish very strongly as we had no more scheduled pit stops to make when I turned the car over to Elliot Forbes Robinson to bring it home.

Elliot turned his customary blisteringly fast laps; making all us young guys look silly. We were not sure on tire wear or fuel consumption because he was going so fast. It was only a couple laps into EFRs stint that the failure that would take us out of podium contention occurred. Coming through turns 5-6 he experienced a toe link tie rod joint failure in the right rear of the car. Fortunately we had a very experienced driver in EFR at the wheel as we have witnessed cars totaled there in that corner when suspension components fail. It was particularly treacherous this weekend as there had been lots of rain the previous week and so all the run off areas were mud. Very sticky mud that tends to send a car flying instead of spinning. In any case, the car was brought by tow truck on the hook into the garage, we fixed the rod end quickly, gave it a rough alignment, and sent Mr. Robinson back out on his way to make laps as best he could. At this point I believe we were down to around 10th or so in ES class and 20th or so overall. Elliot was simply on fire. He was on a mission to get as many spots back as he could, and did a fine job of that working us back up to around 5th in class going into the last half hour of the race. Again, we were looking like we might pull something off, even with all the unscheduled issues.

He was going so fast, about three to four seconds per lap faster than any of us had gone previously during this race, that we were pretty sure we were going to have to bring him in for tires and a splash of fuel. Not what we wanted to do, but the air jacks and the dump cans would be put to the test.
We decided we would go until the warning lights came on for fuel levels on the dash and see how far he could get. Unfortunately, in the last twenty minutes, we experienced a failure with one of the inner constant velocity joints on one of the axles. We still aren’t entirely sure what the issue was at this time as we haven’t taken everything apart yet, but one theory is that the exhaust may have needed shielding on the inner CVs, and that the heat finally got to the CV boot and caused it to come apart. Then the grease was lost from that CV and eventually, after the heavy use, the outer race failed and the balls came out of the CV. Had this been a 24 hour race we would have been fine, but this is the longest race in North America, and what works for other races, in many instances, just doesn’t cut it here. In any event, with twenty minutes to go, and running in 5th place, we experienced ANOTHER mechanical failure.

At this point many said we should hang it up, throw in the towel, and call it quits. That isn’t this team’s attitude, and that isn’t Elliot Forbes Robinson’s attitude. He stayed in the car and we ran and got another spare axle. With 56 seconds left in the race we managed to put the rear of the car back together, and get EFR back under way so that we could at least claim rights to finishing 2012’s 25 Hours of Thunderhill.
Turns out we not only finished, but came in 7th in class and 19th overall out of 69 scored finishers.

To say that our strategy was once again tested and once again proven to be the right balance of speed and longevity, as far as pit stops are concerned, would seem to be a 100% accurate statement. As is ALWAYS the case with this 25 Hours of Thunderhill event, we learned a lot as a team, and will be back next year stronger and faster.

There now, didn’t you also forget about the worries of the world, if only for a few minutes? It’s the journey my friends, it’s the journey.

kabacj
12-24-2012, 09:20 PM
Thanks for taking the time to do the write up crash. You guys are doing the torture test for us to see just how long parts on the GTM can last. Huge effort just to finish a 25 hour placing well is an achievement . You guys did a great job. Thanks for sharing your experience and the lessons learned.

John

sk7500
12-25-2012, 02:46 PM
Awesome Recap Crash!!!
Thank you.
Regardless of how you finished, you guys are the GTM HEROs.

vnmsss
12-25-2012, 07:08 PM
Thanks for the great re-cap, Mike.....Having had the privaledge of driving with Team PDG in the past, and in fielding my own team with our FFR bretheren for some six years, words cannot begin to express the admiration I have for the heart and soul effort put forth by your team.

You did a magnificent job of painting a great picture of what it's like to actually run and finish the 25 Hours, and I would encourage anyone who's up for the adventure, to show up and throw in with your team for the ride of a lifetime.....Kudos to everyone with Team PDG for another outstanding effort at the 25 Hours this year!!

Karen

skullandbones
12-26-2012, 01:44 AM
Congratulations on the repeated recoveries during the long event! That in itself is amazing. You must have some pretty fast wrenchers on that team. Hope you are able to improve on the suspension issues so you can keep concentrating on racing more. Great account of the race, Crash!

Thank you,

WEK.

Movieman
12-26-2012, 07:15 AM
Excellent read and you did something very few people can do: You brought us there with you. I could feel the emotion, the heartache and that isn't done often.
I wish you the best for next year and from what I read, you now know most of the potential weak points of the car.
We'll look for you to be at the center of the podium next year!

crash
12-27-2012, 02:39 PM
Thank you.

Yes every year seems to bring up new weak points as we make the car faster and faster. I think for this coming year we may actually make the car SLOWER and more reliable. It is always a fine balancing act, and I think we may have gotten carried away with the "go fast" stuff without proper testing. We can continue to go fast, but need to run smarter as well.

crash
01-04-2013, 11:56 AM
I have quite a few pictures, but since this site limits picture size greatly, I am posting them over on the other site.

Desertrunner
01-04-2013, 04:55 PM
Which site is that?

crash
01-07-2013, 10:10 AM
www dot ff cars dot com

noother
01-10-2013, 08:11 PM
I'll throw up some pics

http://i617.photobucket.com/albums/tt260/noother268/DSC_0099007_zps96f69341.jpg
http://i617.photobucket.com/albums/tt260/noother268/DSC_0134041_zps5bb1c855.jpg
http://i617.photobucket.com/albums/tt260/noother268/DSC_0418083_zpsb20bbeab.jpg
http://i617.photobucket.com/albums/tt260/noother268/DSC_0120028_zps6d2acf75.jpg

noother
01-10-2013, 08:26 PM
there seems to be a tradition developing.

2012 25 hour:
http://i617.photobucket.com/albums/tt260/noother268/DSC_0414079_zps089c4938.jpg

2011 25 hour:
http://i617.photobucket.com/albums/tt260/noother268/iphone592_zps430fb48f.jpg

crash
01-11-2013, 02:17 PM
That's cool about the smiley face. I wonder who put those on there? :)

David Hodgkins
01-11-2013, 03:11 PM
Crash, I'm sorry about the pic size issue you are experiencing. What minimum size works for you? I'll run some tests in another thread to make sure we can accommodate a decent size pic. Sorry for the hijack; great write up!

:)

crash
01-11-2013, 03:29 PM
The largest one I have been able to place on the other forum is 2150X976 as a .jpeg. That's WAY over what their stated limits are, but they seem to load. I also had a few that were too big for them as well.

tirod
01-12-2013, 11:08 AM
No need to hear it from me, a 7th place is far better than a DNF. And we really appreciate your discussion of what breaks in that situation, and why.

For the less experienced, about how often do you change brake pads? I hadn't even considered it needing to be done until I was reading up on other 24 hour races, and the need to do it and do it quickly. It brought up the whole point of why some teams install on board jacks and the advantages of certain caliper types. It's obviously way different than street equipment going 40,000 miles. I can see the rotors being tossed, too, and those NASCAR videos of fire breathing brakes imply they couldn't hack 25 hours at that level.

crash
01-14-2013, 10:24 AM
We changed pads once during the 25 hours this year. We were trying larger brakes and bigger rotors with the idea that we would not have to change the pads at all this year. We got conflicting reports from different pad manufacturers. The guys that sold $1000 a set pads told us we wouldn't be able to go 25 hours with what we were running. Looks like they were correct. We may try the $1000 pads in the near future, but since we had a sponsor for the brakes this year, we went with what they sent us. Brakes are always an issue, and we were going much faster this year than previous years. That showed in lap times that were 5-7 seconds PER LAP faster. That doesn't seem like much, but over 600 or so laps, it makes a BIG difference. We also had air jacks for the first time this year. They worked very well, and I will be offering them on the www.myraceshop.com website later this year.

PDG team member Jim H made piston retractor tools this year as we went to 6 piston calipers that made it very difficult to get the pistons back without the use of this tool. They worked well and allowed us to retract all 6 of the pistons in about 2 seconds.

Brakes are actually one of our biggest expenses. We could easily use the modern technology brakes to be able to go the 25 hour distance, but they run around $20,000 per set. That would mean taking our brake budget from about $200 per hour to around $800 per hour. That's a big increase.

This game really all comes down to money. We could run race gas too and gain 100-150 HP, but we would more than triple our fuel bill. We could run sticky race tires...tire bill? $50,000. That's for JUST the 25 hour race.

Many people do not understand the costs involved in running a race operation at the upper levels. They hear big $$ numbers and assume the drivers and crew are just getting paid huge amounts of money. That just isn't the case in most situations. The tools to go fast, particularly tires, fuel, and brakes, cost BIG $$ and are replaced frequently.

ehansen007
01-15-2013, 01:14 PM
That is awesome! Great write up and great job overall.

mendo
01-21-2013, 09:03 PM
I got the opportunity to tour the shop today with Richard and Yvonne, ask many questions, poke my head around the car, see all the stuff.

they are great people!

the car is REALLY Impressive!

they know what they are talking about!

believe me, it is a SERIOUS CAR! they have probably broken, redesigned, replaced and improved more parts than are installed on my car so far and they were very up front about what must be done to work on the track and what can work on the street because YVONNE HAS HER OWN GTM TOO! it is red and very nice! I will be going back in two weeks to purchase some of their leftover stuff and will beg for a ride!! keep you posted!

tirod
01-22-2013, 09:17 AM
Piston retraction? Hmm. Just read something about that, was it Mark Donuhue's team in Trans Am, anyway, they used a vacuum system. Applied a port to the reservoir and literally depressurized the brake system with vacuum on the safe side of the diaphragm in the lid, which allowed ambient air pressure to push the pistons back.

Like the air jacks, the boys of the '60s had some clever ideas.

GTM RACER
01-29-2013, 02:43 AM
great write up and recap. What is in store for 2013 for u-guys? Will it be the year of the GTM?