Surely there are plenty of e36/46 bmws in the states with lower diff ratio's than you quote? Mines a 3.45 from a 318is, the 328i iirc was a 2.97
diff, early e36 m3 was 3.15 etc and thats before you look at the different larger series cars.
Good job perservering with the project although I too would only be interested in a selectable when moving overdrive to be worth the effort replacing
my current mnr box.
OK, so it's £718 plus shipping plus import duty. That buys me an untested unit that comes with no warranty from a relatively unknown
manufacturer and it can't be changed while driving. To be honest mate I don't think you will be getting too many buyers this side of the
pond.
To be fair to you it does look like a quality item but being a brand new untested design I would want to know exactly how it was built before I spent
that kind of money. Just a couple of observations: how do you mount it to stop the whole thing spinning? Why oh why did you make the shell in carbon
fibre? Aluminium or steel surely would have been cheaper and easier to make and you are never going to see it.
Photo Archive
Building: Finished MK Indy with Volvo T5 engine
posted on 28/6/13 at 12:49 PM
I agree with the comments on the business model; I don't see anybody buying an unproven product from thousands of miles away with no
warranty.
Don't see a problem about the lack of dynamic overdrive shifting though - you have six gears available at any given time from the bike
'box, why would you want any more? This is more like an easily changeable final drive ratio, tall for road, short for track.
Well, perhaps I should consider a tester in the UK? I will be willing to do that if someone wishes. Its a far way over the pond and some type of
contract would have to written up to ensure my product is returned to the states after testing. I'm currently seeking a tester in the states in
my area right now. I have a potential tester on the west-coast with a Mini/VFR setup.
I had no intentions of selling my product without testing; right now i'm just promoting the product.
As far warranties, well, i'll probably will need to do some research on the competitors. I know for sure they're products have been
proven but i'm uncertain that they offer any warranties as well?? And yes, unknown + unproven + no warranties = no sale across the pond
For me as a start-up in a niche market where few sales are expected, I chose the carbon-fiber/Kevlar cover because its cheaper and more convenient to
manufacture (in my shop). I researched and tried the alum or mild steel route and most shops wont take on small orders, plus they cant seem to get the
CNC radii bends right on the corners. And Westfield, Nova and Quaife with the two piece T6061 alum housing still appears to have oil leaking issues,
whether it be the around the shaft bearings or the casing split?? I purchased a EuroTech FR2000 back in 2004 off ebay to put in my car. It worked ok
and occasionally would lock-up; it spewed oil out the shaft bearings and leaked around the bearing housings/cover mating (no metal or rubber gaskets).
I took queues from this unit to design the R-falcon.
I will concentrate this weekend on making a youtube video on the break-down of the R-falcon. We'll look into the internals and seen how it
works. Back to the proven: I know the internals are proven (gears and shafts) because they're Suzuki OEM parts.
I think the manual overdrive is a better selling point in the states. Builders over here have asked for it. They're probably not familar with
the low diff ratios found in the BMWs.
Photo Archive
Building: Dax Rush - very, very slowly....
posted on 28/6/13 at 03:01 PM
quote:Originally posted by yahshuatwo
I think the manual overdrive is a better selling point in the states. Builders over here have asked for it. They're probably not familar with
the low diff ratios found in the BMWs.
I think its quite a good idea
a bit like on a jeep/landrover, you have a high ratio for the road and alow ratio for off road
like matt_claydon said on this you'll have your crusing/high gear for the road or really fast tracks
and your sporty gear for the tight twisty bits
same way that racers change ratios for different tracks but without the hassle of changing the diff/gearbox
the BMW diff's do have some decent ratio's, but from what I've seen they are quite big and heavy and don't have a reverse
Received the newly heat treated overdrive gears yesterday. They have Rockwell hardness around 55-57 HRC.
this will get the job done! Gear on the left is C45 steel; I had a shop cut the internal spline profile out using EMD, then it was heat treated.
on the right is a make shift gear (bored and weld in spline) used for development.
Final design been in the car for two years , built prototype three years ago. been up and down street in the car, but limited use cause car still
unfinshed after ten years
reverse is a no.brainer,.overdrive works great but need more thorough testing..
We finally come to a point where serious testing can take place with R-Falcon reverse box. Carbon fiber/Kevlar cover is holding up very will. I
mounted the unit in the chassis over the weekend and took a short cruise around the community. The next step will be to dyno it at high rpms and see
how stable it is. Then off to the track. And Yes, I will install steel mesh around the shaft tunnel just in case....
Unit isn't leaking oil; will do further testing on the reverse and overdrive gears
Back to the proven: I know the internals are proven (gears and shafts) because they're Suzuki OEM parts. 
