Author: Tatu Toivanen, Metropolia Motorsport

After really hard work HPF009 is finally ready. This racer is 7th evolution in our team history. The achieved experience with the former racers had helped our working with the car and it had offered to us a good starting point for planning and construction. We have learned one's lesson and we have tried to develop something new as well.

New constructions

The biggest changes comparing to the last years car has done in the chassis and to the brakes but also the engine has improved.

Biggest modification in the chassis has been changing the tyres under the Hoosier brand, the introduction of the new shock absorbers from Sachs brand with the additional fluid tank lines and the new carbonfibre wishbones.

We have reconstructed the brakes completely and according to the tests, the brakes works better than ever. Our disks are laser cutted to our design. For this season we have selected more compact and powerful four piston brake calibers that are all the same in every corner.

For the engine we have invested to improve the endurance and tried to get more power and torque from our Yamaha R6 ´08 engine with the help of the variable length intake 3-phase manifold. New innovation is also the drysump lubrication and the electric water pump.

Car electronics has been updated and made better. Biggest weight savings became from changing from traditional lead-acid battery to lithium iron phosphate battery. Semiconductor relays also makes possible to control the amount of power used in auxiliary devices and save energy. Some updates for gear shifter control unit has been made for improving shifting time.

We are using Motec ADL data acquisition for analyzing chassis and engine data. In our car we have got over 30 sensors what we are logging. In addition engine control unit collects all information regarding engine operation and sends it to ADL via CAN-bus which records all information for later analysis.

Development work

We have used Alphaforms´s rapid prototyping to create our intake manifold parts and cast models for magnesium parts. For the planning of the components we have used cat program CATIA V5 R17.

For the manufacturing of the magnesium casts we have applied the investment casting manufacturing technology. The most of the metal parts for the racer we have machined by our selves in Helsinki Metropolias unit at Kalevankatu. We have used light composite materials for as many parts as possible for instance driveshafts, floor pan which makes chassis stiffen and tailboard, impact attenuator and wishbones.

Specs of HPF009:

Dimensions:

• Weight: ~200kg
• Weight dispersion: 47/53
• Wheelbase: 1620mm
• Track: 1165/1130mm

Chassis

• Frame: Steel tubular type frame.
• Suspension: Double unequal length A-Arms. Push rods in front and rear, Sachs dampers.
• Brakes: Lasercut mild steel discs, ISR calibers in front and rear.
• Wheels: Keizer 3pc 6,5"x13" with single bolt fastening.
• Tyres: Hoosier 20,5x7,0-13 R25B.
• Electronics: Motec ADL data acquisition system, solid state relay system.

Powertrain

• Engine: Yamaha R6, naturally aspirated with mandatory 20mm intake restrictor.
• Displacement: 599cm3
• Compression ratio: 12.8:1 Drivetrain: 4-gears, Drexler friction plate differential with adjustable ramp angles, electronic/pneumatic gearshift system.
• Power: 71,5 kW/11500 rpm
• Torque: 68 Nm/8500 rpm
• Engine management system: Motec M880 with integrated traction/launch control, wide-band lambda and datalogging.

Performance

• 0-100km/h: <3,5s
• Top speed: >160km/h