https://www.wtbaldwin.com/home daily 1.0 2025-07-18 https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/903c3641-ecdf-4299-bbc5-9f7808cf8f73/IMG_0221.jpg https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/d3c8230e-e4dc-448a-9d06-108a243622a5/Screenshot+2024-06-28+122821.jpg https://www.wtbaldwin.com/contact daily 0.75 2024-07-04 https://www.wtbaldwin.com/projects daily 0.75 2024-07-16 https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/4cb58acd-e247-4e7f-b277-a9684f4bc4c4/Cover+cam.jpg Projects The CAD model of the replacement coil pack cover. This was designed with draft angles to allow the part to be easily removed from the mold. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/5bb58aaf-666f-4f39-b4d4-e2971ffc6d67/cfd+oil+catch+can.jpeg Projects One of the byproducts of making over 1000hp is excessive crank case pressure. I designed a custom air oil separator and modeled the air velocity in CFD. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/f0820bda-5286-4362-8923-9b783b91bdd7/Mold.jpeg Projects The initial design of the mold which include integrated vacuum ports and air ports to assist with de-molding. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/4f2e7e1c-5ee8-4226-96f6-d9a79029145d/GTR+emap+and+EGT.jpeg Projects I made a custom made turbo manifold that incorporated individual exhaust gas temperature probes and a exhaust manifold pressure sensor. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/030d4de1-e566-4f08-ac5e-41d022f172c5/mold+machined.jpeg Projects The mold after it was machined. This was completed in three operations due to the complexity of the vacuum and air ejection ports. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/f3408bec-a5eb-405c-839d-57ebf41a21aa/welds+on+turbo+manild.jpg Projects In order to keep the turbo in its efficiency range the waste gate placement was critical. This ensures that the turbo responds correctly to closed loop manifold pressure control. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/1720139717749-YKLFZ59RTABBFSYDEJUN/View%252Brecent%252Bphotos.jpeg.jpg Projects Using the 3d design I was able to create a flat pattern in Fusion 360 and the prepreg carbon was cut out. the material was laid into the mold in a +45, -45 fiber orientation which helped increase torsional ridigity. There was also reinforcement material added around bolt holes to increase strength. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/1720132736430-RHP2KF54H77PY3PVQH85/aluminumwelds.jpg Projects In order to make 1000hp the engine requires a turbo charger. To size the turbo correctly the engine air flow requirements and pressure ratio need to be calculated. Using that information I was able to spec an off the shelf turbo charger that would create a responsive engine. The Turbo would require custom made aluminum charge pipes. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/b7564d86-9de3-4e8e-ba4d-25da444117a0/Carbon+cover.jpeg Projects The part removed from the mold after it went through the required temperature cycles in a custom made autoclave. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/4b0f1412-0945-40e3-a94b-d7da5737c24f/rollcage.JPG Projects With 1000hp the car requires a roll cage. Using NHRA guide lines I fabricated a roll cage out of 4130 chrommolly. This required the entire roll cage to be TIG welded to prevent altering the material properties. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/f541de4c-83e7-402c-bb9e-cd624abc7e16/Cover.jpg Projects The finished product installed on the car. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/474c5b75-be3f-42e1-91a8-82a7727f4a58/rollcage+pt+2.jpg Projects One of the challenges with the roll cage was to get it to fit properly in the car. Sections of the car were 3D scanned and then the cage was modeled in Fusion 360. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/74df89b6-5b1e-40f0-8657-5e9297f510ef/wheel+speed+sensor.jpg Projects In order to acquire accurate vehicle speed all four wheels were equipped with hall effect sensors and custom tone rings. With this data I was able to create a two stage traction control. When the car experiences wheel slip stage one is to increase pressure to the clutches in the transfer case. If wheel slip continues to increase stage two is a reduction in engine torque. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/d65bd816-19ab-40cc-8304-3a89f07fdaba/camsensor+data.JPG Projects Looking at the signal from a custom designed cam angle sensor. This used off the shelf hall effect sensors and a custom made tone ring. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/1719980082504-DNGOE4EY2Z23RFA6QEST/intercooler4%2Bvelocity%2B4.jpg Projects One of the downsides of using a turbo charger is increased intake charge temperatures that decrease air density. Using CFD I designed an intercooler that minimizes frictional flow losses and allows and maximizes the intercooler efficiencies. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/1720035930134-VRACRKJYKORMTWCIDTPM/3d%252Bscan.jpg Projects After discovering that there are some major size deviation between the two valve covers the best option was to 3d scan both covers and design the bracket in Fusion 360. The major challenge with this was ensuring that the coil packs and bracket were in the correct position, radially and axially with ensuring that these components can easily be installed. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/822dd121-c734-4703-811a-4ec467488c7c/72383137117__61690637-C0B8-4305-B3BD-0072EE083F6C.jpg Projects The first several bracket prototypes were 3d printed, using FDM. this insured that the coil packs were in the correct location and it allowed for all the components to be easily assembled. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/9bed15d9-3637-49f4-ab4b-5840d429d02a/machine.jpeg Projects The machine that was used was a three axis so there would be a minimum of two operations. The origin was based off of cylinder one bore and the fixed jaw of the vice. This ensured that when the part was flipped over for operation two there would be dimensional accuracy between both operations. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/0a754cbe-63cf-48aa-8e21-6008a23a998b/IMG_0436.JPG Projects The first bracket completed. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/e198dd3d-ebfb-4d0a-996f-81766d783b1f/wireharness.jpeg Projects I used MIL-STD-681F as a guide for the harness, this ensured that the harness was manufactured to standards that would eliminated the chance of any improper crimp and the harness would survive in the harsh environment of an engine bay. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/cdd7ff91-ce84-441f-8b81-fe9da6bd0867/IMG_0678.jpeg Projects The bracket and wiring harness installed on bank two of the engine. https://images.squarespace-cdn.com/content/v1/667f14ebc0a6a847398c794a/5bb94183-7b40-4293-9e02-9b2c6eb73ec6/IMG_1036.jpg Projects Both finished brackets and the completed wiring harness.