Month: February 2016

CAE Shifters: The Shortest Throws for your Porsche 911

CAE Shifters: The Shortest Throws for your Porsche 911

If you track your Porsche, BMW, or really any other car, you know the value of precise, accurate shifts. Traditionally the best solution to sloppy OEM linkages has been a variety of aftermarket short shifters that reduce the length of gear changes, usually increasing effort and making the lever more ‘notchy’ as a result. But CAE Racing has the ultimate solution for any street or track car- their CAE Ultra Shifter. A work of art, CAE shifters are precisely engineered to provide the ultimate in H-pattern upshifts and downshifts while requiring minimal modification and changing of factory parts. This results in gear changes that are almost as fast and accurate as a fully sequential transmission but at a fraction of the price.

 

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This particular shifter is designed for the 964/993 C2 chassis

 

Having the engine and transmission located at the rear of the car means that Porsche’s offerings traditionally benefited from relatively direct shifting. Early 915 and G50 transmissions used a rod style linkage that directly connected the shift lever to the transmission’s tail housing, making shifts anchored and direct. There are certainly improvements to be made, the U-joint style shift couplers, for instance, tend to get loose with age making shifting vague and gears harder to select. When the 986/996 chassis debuted this all changed though, as Porsche modified its rear-engine supercar to use shift cables instead of a solid linkage. Although both of these systems have positives and negatives regardless of model, a CAE shifter can make all the difference in the world to either transmission setup.

 

Machined from billet aluminum, CAE Shifting Technology has been producing these works of art for a variety of platforms for years now. Combining the finest in German engineering and manufacturing, each shifter is constructed primarily from aluminum to ensure lightness and strength. This from-scratch design allowed CAE to engineer an extremely tight and precise shifter that maintains the factory H-pattern while reducing shifts from a throw to a snap. Their exacting design and impressive results has led to a couple of copy-cats on the market, but nothing matches up to the original in terms of manufacturing quality, precision and functionality.

 

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CAE Ultra Shifter in a customer car along with Rennline Pedals, Floorboards, Track Mats and Glove Box Delete

 

One of the downsides of cable shifted transmissions is a tendency towards being vague and feeling unconnected. This is because there is no ‘hard’ link directly from the transmission to the shifter- and this problem is greatly exacerbated during hard driving, whether through canyons, over your favorite mountain, at an HPDE driving event, or during wheel-to-wheel racing. CAE addresses this by providing a precise gate on the shifter itself that translates to the exact same movement of the cables no matter where the transmission is in relation to the shifter box. It is beyond impressive that they have achieved all of this while retaining the factory cables- yes, every 996/997 unit is designed to work with the stock shift cables, although CAE does offer its own upgraded units which further highlight the capability of this piece.

 

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One of CAE’s BMW offerings bolted into a serious racecar interior. Don’t see your vehicle on our website? Just email us Orders@Rennline.com and we can more than likely get you one of these for your own street or track car!

 

Simply put the CAE Ultra Shifter is the current pinnacle of shifter design. Creative engineering combines with artful manufacturing, precise design and gorgeous looks to create the ultimate package for getting into the next gear. Short of investing thousands on a sequential aka ‘dog box’ transmission with straight cut gears, you are not going to find a more track-ready solution for maximum control over your gearbox. Everyone we know who has driven a car equipped with one of these billet beauties, whether seasoned track veteran or casual enthusiast, has been impressed by the accuracy and control these short shifters give you over whatever transmission they are attached to. So much so that merely referring to them as a short shifter almost feels egregious. CAE shifters are in a league of their own, and that is why we have chosen to offer them for sale right along side our own Rennline parts and accessories.

 

You can find our complete line of CAE shifters at www.Rennline.com if you do not see your vehicle listed please contact us Orders@Rennline.com or (802) 893-7366 to see what we have to offer for your make and model.

 

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One of our favorite 964s- Check out @Sparkyvw on Instagram for more pictures of his Rennline and CAE equipped interior.

 

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Another Rauh Welt build featuring Rennline Pedals, Track Mats, and floorboards, along with a CAE Ultra Shifter. This is a very clean example of what a track car interior can look like

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A Modern Mini Cooper Born to Rally

A Modern Mini Cooper Born to Rally

As many of us can attest, life sometimes gets in the way of your favorite motorsport, whether it is auto-x, rally-x, track days, or even concours events. Patrick Munhall, a fellow New Englander, had such a break from rally-x; one that lasted almost 10 years. His triumphant return to gravel came behind the wheel of his R53 Mini Cooper, which isn’t the typical AWD monster that likely comes to mind when discussing rally racing. Built upon a solid chassis with good basic dynamics, Patrick’s success since rejoining the sport has proved the Mini is capable of succeeding in a diverse range of motorsport environments. However, that success has not come free, and this Mini has been torture tested throughout New England as the chassis, suspension, engine and under body protection have been fine tuned for competition in the New England Region SCCA Rally-X series.

Patrick's R53 Rally Mini Cooper

Patrick and his BDC Enterprises Inc. sponsored Mini in mid season form chasing the more powerful AWD cars- and catching more than a few!

 

Almost any experienced driver will tell you that seat time is the most important factor in dropping lap times, and although rally-x is no different, the abuse that a car takes during an event often requires additional vehicle preparation. And that is where Rennline enters this story. Patrick first tried fabricating his own skid plate, and although sturdy enough for most disciplines, during his second event at New England Dragway he managed to catch the front edge in a covered hole and literally folded it in half!

 

First attempt at a homemade skid plate that failed and was replaced with a Rennline skid plate

The Mini’s first skid plate that met its demise at the hands of a rather large hole at NE Dragway

 

A photo of the total failure of Patrick's homemade skid plate

Unfortunately it wasn’t quite up to task when Patrick found a hidden rut on course

 

A Rennline skid plate purchased for Patrick's rally Mini Cooper

Time for a little upgrade! Rennline skid plate ready to go in and provide some protection!

 

Rennline Skid plate installed in Pat's R53 rally Mini

Our skid plates feature OEM quality fit and finish, and are manufactured right here in Vermont from heavy duty aluminum

As their first season progressed Patrick and the Mini came into their own, going from 3rd in a small field of entries in their first event to a 2nd place finish by their 3rd event. Had it not been for a cone that jumped out into the middle of the course causing a penalty, they would have found themselves in first after the final run of the day. Results like that make you want more of everything, and so the modifications began piling on. To maximize grip Quaife provided one of their legendary torque biasing limited slip differentials (LSD) which can transfer power from wheel-to-wheel based on the amount of slip it senses by using a series of helical gears to transfer load to the wheel with the most grip.

 

A quaife differential ready for installation in the Mini's transmission

The Quaife arrives!

 

The new differential being pressed together

Time to keep those wheels spinning in unison!

To keep the engine firmly connected to the drivetrain a Valeo flywheel and clutch package was added along with refreshed axles to deal with the strain of competition. To get a rally-appropriate ride height Patrick fabricated 1/2″ spacers for the strut mounts which raise the ride height of the Mini that same 1/2″. Powerflex control arm bushings stiffen the suspension and help to retain as much of the factory suspension geometry as possible, and a BSH lower engine mount reduces the amount the engine and transmission can move as they hammer through gravel, mud, snow and muck in pursuit of victory. Most importantly these modifications were carefully chosen to compliment the already agile and able Mini chassis without adding any exotic or expensive parts to the mix.

Custom strut mounts for lifting the mini

Custom strut mounts to help gain the Mini some ground clearance

 

Rear suspension with custom strut mounts installed

Suspension back in, ready to rock and roll- literally

 

With the handling well sorted and the mini protected, it was time to turn attention add some power by turning up the boost in this little Mini. A Way Motor Works supercharger pulley was installed which is 15% smaller in diameter resulting in a supercharger that spins faster and creates more boost pressure across the rev range. An Ireland Engineering exhaust minimizes exhaust back pressure allowing the engine to breathe easier at these power levels. Way Motor Works claims up to 20hp from this modification alone, but when you’re on rally style surfaces power is nothing if you can’t put it down. To that end Patrick runs Black Rocket Rally Tires on gravel surfaces and switches to Bridgestone Blizzaks for the ice and snow events that cover half of the year’s schedule here in New England.

 

The R53 Rally Mini on its gravel setup

Gravel setup

 

The R53 Rally Mini on its snow and ice setup

Winter mode aka 6 months out of the year

 

Finally it was time to turn attention to the interior because to be fast you need to be in the correct environment both mentally and physically. Again a few choice modifications were planned to enhance the Mini without ruining its inherent strengths. A set of our Rennline track mats were installed to enhance footwork and keep the footwells clear of debris that could lodge itself in, behind, and around the pedals. An OMP wheel helps navigate turns faster and helps reorient the wheel when things get get a little too crazy. A Megan Racing short shifter reduces the length of gear changes and adds accuracy to the feel of the transmission. This winter saw the installation of Sparco race seats for both the driver and anyone brave enough to strap themselves in next door, which will come in handy during events like the Vermont Winter Rally which is organized by local rally legend John Buffum.

 

Rennline Track Mats and Sparco Seats in this Mini

Sparco race buckets and Rennline Track Mats make for a race friendly interior

 

A picture of Patrick's proper racecar interior

All business, no frills; just the things a pilot needs for some full-speed fun

 

For his time, effort, and dedication Patrick has been rewarded with a Mini that can go toe to toe against more powerful and grippier cars on almost any terrain. We are just happy we were able to help him in his goal of improving the reliability and drivability of this cool little car. With our ever expanding line of Mini Cooper parts and Patrick’s desire to continue improving the car and his skills, we are sure there will be another update coming in the near future. If you are attending a New England rally cross event in the coming months, keep an eye out for Patrick and his Mini atop the podium!

 

Patrick's BDC Enterprises sponsored Mini ready for the 2016 season

Patrick has his Mini fine tuned and ready to vie for the title in the 2016 season

 

Race car life!

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“Minor weight reduction” aka making the car faster, handle better, and easier to drive all at once

 

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Rennline: Continuing Expansion

Rennline: Continuing Expansion

Here at Rennline we are lucky enough to have a devoted customer base that understands our commitment to quality parts and dedication to customer service. This relationship has grown in size and breadth over the years; it saw us expand from a small industrial space in downtown Winooski, Vermont into our current building, and now it is allowing us to build on that foundation. Both literally and metaphorically. But none of this would be possible without each and every customer, so again, we would like to thank everyone, from the smallest order to the largest, for their support of Rennline Inc. and the parts we manufacture for your Porsche, BMW, Audi, Volkswagen, Mini and more!

 

The entrance to the addition

The entrance to the addition

 

The addition getting close to finished!

Getting close to finished!

 

 

The left side of our new space

The left side looking from the door from the existing building

 

The right side of our new space

The right side looking from the door from the existing building

 

One of the most important aspects of this new space was what to name it. After a few days of deep contemplation, waterjet operator John Bombard emerged with the answer: his ‘office’ would henceforth be known as “The Jet Hanger.” Of course, despite completion of the naming process there was still much to do to finish the transformation of our addition. Plumbing and wiring needed to be run, drains, grates and filters installed in the floor to catch overflow water and filter our the garnet which is a super-fine abrasive that gets injected in small amounts to aid in water jet cutting.

Running the requisite fire suppression systems.

Running the requisite fire suppression systems.

 

Grates with filters for waterjet overflow

Grates with filters for waterjet overflow

 

Preparing the sprinkler system for installation

Not quite as aesthetically pleasing as our own extinguisher mounts!

 

Beginning to move the jets meant a lot of muscle was needed. These things keep about 10,000lbs of abrasive sand in the tank and about 8,000lbs of water (128 cubic feet)- PER JET! We had two that needed to be cleaned out, disassembled, moved and reassembled in the Jet Hanger. This was an all-hands-on-deck kind of day, but luckily we are a hearty folk up here in Vermont and the entire operation went smoothly and relatively quickly considering the shear volume of material that needed to move.

 

Welder Connor and Fabricator Jeremy getting the job done

Welder Connor and Fabricator Jeremy getting the job done

 

Manufacturing Team Leader Buck getting into the trenches himself

Manufacturing Team Leader Buck getting into the trenches himself

 

Clearing out space in the existing shop

Making moves!

 

A HUGE increase in space

A HUGE increase in space- the majority of the open area you see here was taken up by waterjets

 

Getting the first waterjet situated in its new home

Getting the first waterjet situated in its new home

 

The first of the water jets to get back up and running

And we are back in business! Or… at least partially. 1/3 jets back up and running!

 

We took this expansion as an opportunity for us to add some machining capability since we are going to have sufficient additional space. We have had great luck with Flow Waterjet, so we contacted them again for one of their newer units. This was delivered in a timely manner and we began setting up our newest toy… er… machine! This puts us up to 3 waterjets in house, two CNC mills and a CNC lathe along with a couple manual mills, two huge press/brakes, a CNC Time Saver and plenty of other odds and ends to makes sure we can tackle any challenge from any job that might present itself.

 

New waterjet incoming

New waterjet incoming!

 

We had Flow's technicians and engineers come up to Vermont to do the final assembly and calibration

New arm for the new jet! Of course, we had Flow’s technicians and engineers come up to Vermont to do the final assembly and calibration

 

General Manager Tom, Engineer Dave and Owner Paul set up the new garnet abrasive hoppers

From left-right General Manager Tom, Engineer Dave and Owner Paul set up the new garnet abrasive hoppers

 

Flow Waterjet #3 for the Rennline shop

The eagle has landed. Flow Waterjet #3 for the Rennline shop

Things have progressed even a bit further than since these most recent pictures; we are almost back to fully operational waterjet status and the moving/reorganizing process has begun in the existing shop. This will be a lengthy one as we add additional storage racks and finalize the overall layout to maximize space and work flow. Although this operation has already been a huge amount of time and effort and there is still plenty of work to be done, seeing it all start to come together is bolstering us for the final push in getting it done!

 

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