Bradan 575 project The following project is based on a 2002 575 in preparation for the Hamptons Rally. It consists of service, performance upgrades, and detailing. All three aspects will be documented in this thread. We have slightly longer than a week to complete this project and deliver the car for Saturday, August 28th. We hope you enjoy following the process. Stage 1 The car was delivered to us last night. Here are some before images of the vehicle. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Stage 2 The car was shifting into neutral during acceleration which we diagnosed as a worn clutch. We contacted our favorite parts supplier, Ricambi, to overnight us a complete clutch kit. Daniel and Mike came through as always and we had a complete clutch first thing in the morning. Alex started the process by removing the exhaust system and bumper. By lunch time, the transaxle was removed as well as the old clutch. A close inspection showed heavy wear and glazing. The gearbox oil was changed and a new clutch was installed. Our goal was to have the car on the dyno before the end of the day. By 3 pm, the car was back together and ready for a road test to confirm perfect running order. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Stage 3 The vehicle was moved to our dyno test cell. Strapped down and ready for testing, we brought the engine up to temperature and calibrated the machine. Each power pull was done in 5th gear, the strongest of the 575, because of it's 94:1 ratio. The run started at 45 mph and peaked at 145 mph. Each test was done with the hood closed for induction purposes. Between each run, the hood was left open for 20 minutes to remove heat soak. The 3rd and final run produced a staggering 442 hp and 379 tq. Our pre-test estimates were 400-420 whp. This is a strong motor for sure. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Damn, that looks like a twin of my car!!!! Are you still planning on doing ground effects for the rear bumper?
Stage 4 Given the very limited amount of time for this project, the most extensive upgrades we could offer consist of minor intake and exhaust work. So, the vehicle was taken to service once again to have Alex remove the complete exhaust system. After close inspection, it was clear that the exhaust is a major limiting factor in the vehicle's power output. Stage 5 will be posted Monday afternoon. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Stage 6 The mufflers were engineered and constructed this past weekend. The muffler starts out as perforated tubing, sheet metal, and stainless muffler packing. It takes thirteen hours to make a pair from start to finish. Our master fabricator and welder, Ross, starts by bending all the sheet metal to form the case. Then, he assembles the internal chambers. Once fully assembled, the chambers are pressure tested with compressed air to verify there aren't any leaks. Exhaust tip diameter is increased to 3" with a staggered setup. Updates later today... Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Make sure you replace the center muffler resonator with straight, not x, pipes like the factory did in Fall 2003 (AN 51797). That is a pretty strong engine. Assuming 15% drivetrain losses, 515 hp would be 438 rwhp and 434 ft lbs would be 369 rwft lbs. Taz Terry Phillips
Stage 7 With tubing diameter increased to 3", we fabricated the complete center section. Resonators have been removed and catalytic converters have been replaced with a two hundred cell metallic race cats. The entire system from the mufflers to the exhaust manifolds are now complete and ready for installation. Tonight and tomorrow will be spent fabricating the exhaust manifolds. All mounting bungs and flanges are being machined overnight. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
I'm curious to know the following: 1. Just how much of a limiting factor in the vehicle's power output is the factory exhaust? 2. What is the most effective modification, approx. cost and the end result? 3. What is the most cost-effective modification, approx. cost and the end result?
I am still confused and wondering why you are building all of this from scratch when big name highly respectable companies have spent 10's if not 100's of thousands of dollars in R&D developing the exact same thing... seems to me like I would buy a Tubi or any other big name brand.
