Elmer Racing

OEM performance engines. Tailor designed and manufactured for your supercar, race car, and marine use case!

[Elmer Racing @ElmerRacing]

4000hp Hel shorblock test assembly finished, in spec.
Manual clearanced block to fit slightly beefier billet titanium rods. CAD fix for batch 2. Structurally ok though, approved for customer use.
Long block getting ready to go together also! First fully assembled head.

[Elmer Racing @ElmerRacing]

Introducing our Billet Merge Collector 'What could go wrong?' durability guarantee!
1 free replacement, regardless of how it broke. Just send us the pictures/videos and permission to use them. Full terms on the TOS page on our webshop.
So what happened in this customers case?
Based off the images it looks like a combination of factors. Vibrations and thermal expansion loads from the wastegate exit pipe transmitting though the wastegate to the wastegate mounting. High temperatures due to thermal insulation and likely closed floor (time attack car) with minimal airflow around the exhaust. Sharp edge on the *inside* of the wastegate duct to the runners/turbo area. Lots of heat cycles and use.
Due to customer time constraints to get the car ready for the next event, we sent out a replacement collector of the same dimensions, but updated model with filleted wastegate exit (yellow highlight in picture, all our newer models have this update). Other option was to make a custom one from 316 or 321 stainless material, but this would have taken a few more days for raw material lead time.
We also recommended changing out the slip-over fitting for a flex piece. And incorporate a external support clamp between the wastegate and main exhaust pipe.
And if possible, any slight increase in airflow around the header pipe would help reduce peak temps and thermal cycle load.
We think our 5 axis Billet CNC Merge Collectors are the most durable parts available. But sometimes things can happen. If it does, we have your back. And will try to help you avoid another failure.

[Elmer Racing @ElmerRacing]

Could the 2031 F1 engine rule revamp be interesting for OEM race engine manufacturers like us?
Maybe!

[Elmer Racing @ElmerRacing]

F1 going to better regulations for 2030 or 2031?
Elmer Racing engines in F1 maybe?
Definitely would be interesting if the regulations are open enough.
Certainly enough time to build a department.

[The Race @wearetherace]

FIA president Mohammed Ben Sulayem says #F1 is going to V8s in 2031 regardless of what manufacturers want.

All they can do is approve an earlier switch:

https://t.co/b0RsjxiVlP

[Elmer Racing @ElmerRacing]

4000hp v6 first engine assembly progress.
Rods, bushings, pins, clips, pistons, piston rings. All looking good. Tested for rotation clearance in the crank case earlier.
Custom tool to mount piston pin clips in the bottom left of the picture. Crazy stiff clips, hence the need for a tool, but should stay in there even at max rpm (well above 11,000rpm)!

[Elmer Racing @ElmerRacing]

CNC toolpath update for the 4000hp Hel billet tool steel crank looking mint!
No more small corners left over here and there. And much more reasonable tool wear.
Bearing surface polishing/grinding should be much faster and easier also.
The surface shape around the highest loaded areas is especially critical for longevity in a crankshaft being pushed as hard as this.
Peak stress needs to be kept in check, but for longevity it's even more important that the stress levels don't change too rapidly, as that aids crack propagation/fatigue.
This is why our crank designs have a almost organic shape. With the power density we push for in our designs there is no other way to make this work. Design time is crazy high (compared to basic cranks), but absolutely needed.
And the CNC machining side then needs to be able to effectively make these crazy shapes. This also takes a lot of skill and dedication to achieve.
The up side is that at least design criteria wise, we can push these crazy high power densities that are unheard of from other OEM's.
The only reason we even attempted this was how well our Thor crank has performed. Giving us confidence in that we at least know a little about what we're doing.
There are no guarantees in racing or when pushing boundaries. But it's what we love, and what we're good at.

[Elmer Racing @ElmerRacing]

2 Versions of our parallel entry 4-to-1 billet merge collectors now! Standard and the new lightweight.

[Elmer Racing @ElmerRacing]

We launched a new website!
Because that's what you do today!
42MW 43% efficiency in a 40' container
Datacenter ready.
https://t.co/1QtPh2vZIu

[Elmer Racing @ElmerRacing]

Hel test assembly progress update!
All major components fit and are within tolerances. A few bolts need different spec heads, and waiting on a few smaller parts.
But we're getting closer to 4000hp.

[Elmer Racing @ElmerRacing]

Close up look at how hard the design is pushed on our 4000hp Hel engine.
Intake and exhaust valve guides are fully integrated into the port design. And the port cross section area fully takes this shape into account.
The exhaust value guides have a shorter external end taper and different internal diameter for the tip to reduce the temperature of the tip. But still needs to be very close to the valve head to get good heat conduction and valve cooling.
Intake side is fully contoured behind the valve guide hump to reduce turbulence.
At full power both the intake and exhaust flow is mach limited during the entire valve open period. Shapes and maintaining port cross section really matter to help reduce shock waves and port flow losses close to the valve.

[Elmer Racing @ElmerRacing]

Hel build update. Clearances work as intended!
Test assembly continues!

[Elmer Racing @ElmerRacing]

Crank and main bearings fit in the Hel block!
We didn't make some crazy error :)

[Elmer Racing @ElmerRacing]

Note: Once the first engines go out to pre-order customers we will be increasing the engine price slightly.
We ended up having to do more custom order parts than expected, pushing up costs slightly.

[Elmer Racing @ElmerRacing]

Assembly started on our first Hel engine.
Valve seat press fit tolerance spot on!
Big thanks to CHE Performance for helping with material and dimension selection. (Even if we ended up going slightly outside of their recommendations)
Next up on the heads: valve guide install tooling, valve guide install, valve guide reaming, and valve seat machining.

[Elmer Racing @ElmerRacing]

Great success! Our billet titanium connecting rods fit our billet tool steel crankshaft!
Ready to drop into our first 5000cc 4000hp Hel engine and ship out to customers soon!

[Elmer Racing @ElmerRacing]

Some engine parts from our booth at PRI last week!

[Elmer Racing @ElmerRacing]

Two of our billet engines at PMW2025 in Cologne Germany!
Stop by to say hi today and tomorrow!
Happy to support all your custom OEM engine needs, as well as billet merge collectors and other engine components.

[Elmer Racing @ElmerRacing]

Locked in for PMW2025 expo tomorrow and Thursday.
We design and manufacture bespoke OEM engines.
Especially good at very high performance and/or small amounts.
And make billet merge collectors and other engine parts.

[Elmer Racing @ElmerRacing]

We specialize in designing custom engines. But have a few off the shelf designs:
https://t.co/UQ4TfkCN0K

[Elmer Racing @ElmerRacing]

CNC machining process for the billet crankshaft on our 4000hp 'Hel' engine.
(Hel is a "bolt-in" replacement for the Nissan vr38dett)