Category Archives: design

Hancha BRZ/FR-S/GT86 Front Bumper Design

Lawrence has been hard at work to get started on our front bumper design.  This is what he’s done so far.  This is not a final design, we are going to keep tweaking the aesthetic, then run it in OpenFoam to get the results, then tweak it a bit more based on our results.

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Aero Development Begins

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We got our hands on some OEM bumpers and I will begin designing a lip kit shortly and Paul  will tweak it based on his CFD results.  Lawrence will get started on designing our aero kit shortly, but here is the basic concept

We wanted to create something simple and clean.  For BRZ owners, you will be able to retain the DRL (since it’s one of the coolest features).  For FR-S owners, you can retrofit BRZ DRLs or use one of the optional covers we will make.  The front bumper will cover the bumper beam as well as have a lower, flatter, even chin for a cleaner look

There also be an optional lip as well as splitter available.  The pieces will be made of fiberglass, but we may offer a carbon fiber option.  We are still working on designing the rear bumper and diffuser concept.

Interior Parts Coming Soon

First, parts for the BRZ/FR-S/GT86.  A replacement AT paddle shifter

PaddleThe paddle will be 40 mm taller overall, 25 on the top side and 15 on the bottom.  The bottom can not be made any taller without running into the cruise control stalk.  However, this should still be large enough to be able to shift with your hands at the 2 and 10 o’clock position or 5 and 7 o’clock position.  If we can reuse the OEM electronic box, we will have a core exchange program.  If we cannot reuse the OEM electronic box, we will make a custom box, and try to create an adjustable spring tension system for those who want to a heavier shift feel and would like to customize it to their preference.

Paddle Shifter

We are also making two shift knobs: a Delrin piece

Tall Shift KnobIt will be 90 mm tall, 50 mm in diameter, and weigh about 200 g (roughly the same as stock).  The other shift knob is a titanium piece:

Ball Shift KnobIt will be about 55 mm tall, 50 mm in diameter, and weigh about 215 g (slightly heavier).  We were also commissioned to create a SR20DET to E30 swap tach signal converter.  We were going to use an off-the-shelf enclosures but they were all too large for our liking

picture137Unhappy with this solution, we are creating a custom enclosure.  The part will be made of billet aluminum, with a machined down bread board, Deutsch motorsport connectors with flying leads.  This is a rendering of what it what Zach is thinking of making

SRE enclosureThis makes for a much smaller, more robust part.

BRZ/FR-S/GT86 Rear Trailing Arm

This is our rear trailing arm concept

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It utilizes the same aluminum alloy as our lower control arm, with a 7075-T6 linkage adjuster, and an e-brake cable bracket.  Because the arm is a only a tension/compression member, it is not highly stressed so we tried to maximize stiffness and adjustability with our design.  We used 3G’s as the loading condition

The arm

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The fork

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The current assembly weighs would be just under 2 lbs, but we may end up changing the fork to a stainless steel one if we feel the aluminum fork is too costly to manufacture.  We feel this is an acceptable compromise because the linkage adjuster can be sacrificed when galvanic corrosion occurs because they are readily available available and are roughly $20 each.