CSG Brake Pads: Details Make the Difference

Much like tire technology has evolved rapidly in the last several decades, so has brake technology. There are hundreds of brake compounds produced all over the world, and the majority of off-the-shelf brake compounds offered decades ago still exist today. These compounds that may have been great in the past may not be ideal for today’s performance requirements.

CounterSpace Garage have tried to make their mark by putting together a detailed, comprehensive understanding of the entire braking system (across numerous makes and models) as well as the general demands of the entire racing landscape. After spending years testing hundreds of discs, fluids, compounds, and calipers to identify their respective limitations, they’ve been able to satisfy a wide array of performance cars, tracks, and tire compounds.

Contrary to popular opinion, outright braking performance is only one part of the puzzle. Not only are CSG concerned with improving the pad’s outright performance, but they also think about pad control and the context in which the pad will be used. If a pad isn’t suited to the driver’s preferences or the car’s limitations, it will never be used to its full.

To improve control, maintaining consistency is paramount. If the brake pad breaks down, then it snowballs into fluid failure, excessive caliper flex, and excessive disc wear. Consistency also means friction characteristics at different pressure applications, pad modulus through the temperature range, and performance from fresh to the backing plate.

Expending Energy Efficiently

Aiming for a consistent friction material often yields higher pad stiffness, which allows for a more responsive braking feel or “bite.” This doesn’t mean the brake torque is delivered in spikes, which can cause early ABS intervention, but rather with smoother engagement and smoother release. Primarily, the driver feels a more intuitive relationship between his brake application and the way his car decelerates.

Thanks to CSG's custom setup, Gary Wong enjoys reliable, reassuring braking performance in his high-horsepower heavyweight Supra.

Stiffness has secondary benefits including: better pad wear, lower overall heat generation and less heat transfer into critical components like the caliper and hydraulic fluid compared to the existing compounds on the market. A stiffer pad is usually a denser pad, and more material means more thermal capacity.

In order to understand how stiffness plays a role in response, we should use a simple physics equation with the assumption of infinitely rigid structures:

Friction Force (Ff) = Coefficient of friction (mu) x Normal Force (Fn)

This equation helps us visualize the effect of using two different sanding blocks to hold a piece of sandpaper against a sanded surface. A sponge requires more vertical force to generate the same level of friction force at the sanded surface compared to using a piece of hardwood. Now it’s obvious why having a good pad compound can result in better pedal communication and improved control over braking events — it maximizes tire adhesion and improves peak deceleration characteristics more consistently and with less force.

Tailor Made

When we’re trying to assess the level of control their particular pad offers, we consider things like: whether or not they need to build up the threshold pressure, whether they need to reduce their brake pressure carefully like with an aero car. This helps us establish the control objectives,” CSG’s David Leung notes.

“If a driver is dealing with a lot of ABS intervention, a digressive pad can help. As it limits some of that power at higher pressures, it makes it less likely to activate ABS.

Part of Gary Yeung's remarkable speed in his normally-aspirated S2000 comes down to its ability to decelerate, courtesy of CSG.

For cars with aero, a progressive pad might be best. As temperature and pressure increase, breaking power increases at an exponential rate. However, when the aero bleeds off (often very rapidly), this compound makes it easier to reduce pedal pressure quickly enough to avoid lock-up.

All of these profiles are taken into consideration to deliver what is ultimately an intuitive braking experience that allows the driver to focus on other aspects of driving and racing.

To demonstrate the ways in which driver preference factors into the equation, consider just the well-known users of the Supra A90 who’ve partnered with CSG: Jonathan Wong, Jackie Ding, Gary Wong, Allen Patten, Dave Kramer, Drew Turner, and even Toyota Engineering have turned to CSG for their own bespoke setup.”

Thermal Constraints for Different Applications

To get the most from a particular set of pads, some turn to ducting, which helps keep a brake system in its operating window. Some pads need to operate at a much lower temp to generate the performance and better wear (especially pads that generate excessive heat). High levels of heat generation also transfers into the caliper, causing them to get soft, and also transfers into the fluid.

Some pads need heat to perform, which is where ducting can be a detriment, since heat may be required for some friction materials to improve wear consistency in racing situations. Ducting also subjects a brake system to a wider spread of temperatures, which can shorten the lifespan of various components.

Viz paint is used to establish the exact thermal parameters their brakes must operate within.

Ducting does have some benefits especially when you’re operating a spec/homologated brake system that may have undersized calipers/discs (they usually get replaced after each race) and require the brakes to be regulated in a more consistent temperature range.

At the end of the day, ducting should really be a fine tuning tool, not a complete solution to resolve brake issues. It all comes down to designing for the appropriate application and optimizing the performance zone.

Maximizing Both Ends

“We also assess the rear brakes’ utilization. Regardless of whether they’re optimizing their rears to work with the factory bias or they’ve added a proportioning valve, we want the brakes to aid in slowing the car and assisting in rotation.

Jackie Ding's able to make his Supra turn like a much smaller car thanks in part to the well-chosen pads at the rear axle that facilitate usable rotation. 

By maximizing the rear brakes, we can utilize the tire grip from all four corners of the car. Using tire grip from all four tires means better distribution of brake load, maximum deceleration, better wear, and better temperature management to keep the brakes in the optimal operating zone.

A Compendium for All Invested

To take every conceivable factor into consideration is how CSG has been able to develop a wide range of pad solutions. It’s also due to driver feedback and motorsport data, as shared with them by their loyal customers. This information is then filtered down into a range of solutions that meet spirited driving activities to racing at every single level between HPDE and professional racing applications.

"All relevant areas of braking performance must be understood to provide a truly premium product," David adds.

CSG have made countless strides towards finding the right products for most of today’s platforms, They’ve built a compendium of braking data over years through internal development goals, brake dyno work, interacting with their customers, and using their feedback to tailor their products to the customer’s demands. They offer a huge array for different conditions, setups, and for different driving styles.

“CSG is a premium product and the costs reflect that. With that cost, we offer free consultation since we want to meet our customer’s needs and optimize results. All we ask is that they provide data. Ideally, this comes in the form of telemetry, but onboard video, photos, and anything else that can contribute to a clearer picture of what’s happening at the track,” David adds.

The brake system is an ecosystem in itself, which is better understood through constant communication between customer and manufacturer. This interaction is the backbone of CSG’s feedback loop, and only through this and the high-quality data it relies on has high-grade deceleration been made available to drivers of all stripes.

Joe’s M3: Proving His Potential

Photo credit: CaliPhoto

When building a track car, it’s almost always easier to take the paved path. Picking a platform that has been thoroughly developed, with available parts for every possible problem and associated forums filled with information help get the driver to the track without much wrenching.

Not that ease was the main reason Joe McGuigan decided to add an eighth car to his collection — he did that because his friends urged him to try the car he’d avoided for a while. They were tired of watching him struggle with his trailblazing passion projects. They said he’d be able to save himself time if he just joined the tribe and bought an E46 M3.

When Spencer Kimball decided to sell the E46 he’d built for his father, whose injuries prevented him from enjoying it, half of the greater NorCal track community flooded his inbox. Spencer had already proven he knew how to put a seriously quick M3 together, and this example checked just about every box a track car needs to. Plus, the price was impossible to argue with. It would make some track rat a very happy owner soon enough, but an iconoclast like Joe? Not likely.

He was well aware of the M3’s potential, but he never found it interesting enough to build one himself. He preferred the challenge of developing a less-loved car, and always found the E46 M3’s competence a bit boring. Too easy to drive quickly, too easy to build. Not enough of a challenge for a man trying to prove a point.

However, the long list of primo parts and the low, low price were too tough to ignore. Joe had to accept the “boring” car for the simple fact that he would no longer be able to handicap himself with a sub-par chassis. “I could show people how fast I really am,” he added. Rather than prove a point as a builder, he could prove himself as a driver.

He mulled it over for a few days before pulling the trigger. Picking it up on the way home was the easy part. Driving it back to his crowded driveway, it dawned on him how big a task he’d set for himself: “Now I’ve gotta put my money where my mouth is and build a really fast car,” he said.

Fortunately, the car was already well on its way towards perfection. Spencer had big plans for the build and sank a good amount of money into making it fast, reliable, and fun to drive. The short list includes:

• Shaftworks USA coilovers with 500/750-lb springs

• Custom Drexler-style 1.5-way differential

• 4.10 gears

• SPL arms

• Supersprint V1 header

• CSL intake

• HTE tune

• E90 GTS rear wing

• Bimmerworld diffuser

• Bimmerworld 3” exhaust

• PFC ZR45 BBK

• APEX Wheels 18x10" ET25 Forged VS-5RS

Those and a few minor mods were all Joe needed to set some competitive times. The first track day was a few days after pickup, so he only had time for an alignment and a fluid flush. Nevertheless, its first outing in his hands, a two-day event at Buttonwillow, was a success.

He found it fast and forgiving, with a linear power delivery and direct steering. Those qualities, plus a hint too much understeer, helped Joe get on top of the car in a session. By the end of the first day, he lapped Buttonwillow 13CW in 1:56.3 — on an old set of Toyo RRs, no less. The predictive timer showed an optimal lap a half-second faster which, funnily enough, is one tenth shy of his best-ever time at 13CW in his well-developed IS-F.

He’s already sussed out its shortcomings and drummed up a short list of solutions which he plans to implement soon. Being able to knock out problems quickly with the support of a vast market is one of the reasons going with a well-loved platform makes sense. “I plan to move pretty quickly with this build. Who knows? I might sell it next year,” he laughed.

The brakes are capable, but the pads might need to be changed as the initial bite wasn’t strong enough to give him much confidence. The spring rates are too low; the owner before Spencer had specced them for autocross. It’ll receive MCS two-ways, a TC Designs cage, reinforced swaybar brackets, and full Zebulon/Buildjournal aero in the next couple months.

But the bones are good, as they say, and it’s already fast enough to aim for some of the times set by friends and colleagues in the E46 scene. While he hasn’t given up on his IS-F, he’ll fixate on beating the established BMW benchmarks for the time being.

Andrew from Buildjournal has taken his E46 M3 just about as far as anyone on the West Coast has, and his car can turn a lap around 13CW in the 1:49s. “I’m sure its capable of something in the low 1:50s with weight reduction, a better setup, and full aero,” Joe declared. There’s no reason to doubt it.

The potential is obvious, the build is nearly finished, his connections are eager to help him, and all he’s had to suffer is a little boredom. The E46 might not pull at the heartstrings like some passion projects, but he can’t deny the potential that the project holds — and the fun he’s already had with it — has caused him to change his tune.

Michael’s 350Z: Take A Chance, Prove a Point

Twelve years with an unloved chassis has given Michael “Stubz” Hillo a unique perspective on taking the underdog route. There are other established, well-paved paths with minimal maintenance and certain outcomes, but they don’t offer a maverick a chance to prove a point.

Stubz took it upon himself to take the unloved 350Z and make it into a NASA ST4 race-winner because, well, he hated the idea of conforming. However, before he started his mission, he was after an affordable way to begin drifting. Nowadays, the 350Z is one of the few Japanese sports coupes that offers the sort of value the budget drifters offered back in drifting’s heyday. Even then, it was pretty cheap.

It was more than just an option for the cost-conscious drifter, as Stubz realized. Beyond low overhead, a torquey motor, and a rear-drive layout, the Z has a lot going for it. It’s reasonably stiff, the aerodynamics aren’t terrible, and the aftermarket is decently sized. It might not be as well supported as the E46 M3, but it offers similar power-to-weight figures and the potential to run respectable lap times at a fraction of the price.

The zeal and the commitment to proving the platform came later — at first, it was cheap fun. Beating up on pricier cars was only part of the pleasure; the steering was full of feel and responsive, the motor responded well to modifications, and the rear end put the power down decently.

Some of that luster began to fade when he tried to turn the Z into something more than a midfield car. The budget modifications no longer seemed to be enough, and so he tried experimenting with the high-end brands which only offered limited support for the Z.

After testing Penske and Godspeed coilovers, he settled on MCS two-ways with 18K springs up front and 9K in the rear. The car still lacks some of the compliance he’d like in slower corners, but it works well enough in the fast sections, thanks in part to Epsilon+ aero, that the compromise is acceptable.

The most irritation has stemmed from the car’s flawed braking system. Persistent knockback issues and lousy OEM ABS pushed Stubz into spending hundreds of hours diagnosing and attempting to find a package that would work.

Plenty of thrown wrenches and a thousand curse words later, he found a set of Stoptech Trophy big brakes that did a reasonable job. Because they moved the brake calipers closer to three o’clock, they mitigated some of the knockback resulting from the steering knuckle flexing. The remaining bugbear was the ABS system, which needed to be retrofitted with the Bosch Mk60 kit from Race Harness Technologies.

Though the braking system works decently these days, Stubz isn’t completely satisfied. Trailbraking has improved, but the outright braking performance hasn’t gotten much better. However, some of that has to do with the weight of the vehicle, which has been hard to lose with conventional stripping methods. “You’ve gotta get pretty creative when it comes to putting the car on a diet. I didn’t want to, but I had to buy carbon. Hatch, hood, front bumper, and headlight blanks from Spinnaker Composites have helped, but the car is still heavy.” he explains.

It’s transformed into a reasonably swift car in recent years, even with the diminishing returns from spending big bucks on primo parts. The 3,200-pound Z has an average of 257 horsepower which is pretty well administered thanks to 275-section Toyo RRs and the aforementioned aero. A broad powerband helps make the car less track-sensitive than some, and, anyways, Stubz no longer agonizes over finding the perfect setup. After several years of head scratching, he sees the Z as a dependable, safe, and sturdy car which is easy to run and satisfying to drive. Going for the gold isn’t his aim any longer — he’s happy with what the 350Z’s speed. Any car that can lap Buttonwillow W13CW in 1:54 is more than just fun — it’s seriously fast.

Striving to perfect the car sapped some of his ambition, but it’s also given him a few notable wins, wisdom, and a pragmatic approach that provides him with peace of mind. His lack of zeal might not motivate newcomers to try and beat the odds, but if they read between the lines, they should realize that there’s nothing with the Z as an entry/mid-level car. It might not carry an ambitious driver to the top of the podium, but its golden era-pricing lowers the barrier to entry. It’ll help them get involved faster — and in Stubz’s view, that’s better than sitting on the sidelines and dreaming of victory.

Johnson's RX-7: Refreshingly Reliable

Title photo: @Yunnizhai

Misc. photo: CaliPhotography

Running through the spec lists of the boxy cars which caught his eye, he found one member of the Gran Turismo garage with an unusual engine configuration.

Two-rotor, 1300 cc.

That was when the seed was sown. A ten-year-old Johnson Mac had found a car that piqued his boyish interest in machinery. Little did he know that this quirky Mazda would influence the direction of his career, and that, twenty years later, he’d still be tinkering on a rotary-powered car with the same sort of enthusiasm he had at the onset.

Things didn’t take off like he would’ve liked, but perhaps those years of dreaming served to build a foundation he could later build upon. It was the white FC3S from Initial D that got him to scour the local classifieds for an affordable RX-7, but he was a high schooler then without the funds to get one of his own.

First Stage

It wasn’t until a few years passed that he could have one for himself. The primered exterior and stained burgundy interior of his first FC didn’t impress many, but the reliability of the naturally-aspirated 13B engine surprised its new owner. Despite the reputation these rotaries had, Johnson learned that proper maintenance could make one fairly dependable.

That foray with an atmospheric motor encouraged him to venture into turbo territory. With the help of Fris from Lucky 7 Racing, his friend Allen, and the rest of his FAFSA money, Johnson bought an ’87 Turbo II shell, fitted a turbo powertrain, upgraded the footwork, and went autocrossing.

It was only a matter of time before he graduated to track days. After his first time on a road course, he knew he’d found the hobby he’d spend the rest of his days doing. Two frightening crashes and countless nights working in his driveway didn’t deter him from pursuing his passion, but common decency did—temporarily, anyways.

After crashing his second FC, he didn’t want to burden his roomate with another project crowding the driveway, so he parked his rebuild while saving for a house of his own. Johnson had graduated and gotten an engineering job, so the money was coming in, but he was still stretched thin.

Third Stage

Three years passed before he could acquire a house, a grip on things, and, finally, another FC. Right as he was beginning to revive his car habit, his friend from Lucky 7 Racing called about a car that might interest him: a race-ready FD3S that the customer had sold back to the shop. Money was tight, but the timing could not have been better, so Johnson took a leap of faith.

The car had been built to run in NASA TT2 and built to a high standard. In fact, it was mostly complete, save for some paint and wiring issues. It even had a running engine making twice the power of his previous Turbo II’s. He sold off the salvageable bits from the crashed cars crowding his garage and made space for his third-gen.

That was the summer of 2016. Four months and three track days later, the engine blew. “I’d had some issues with breakup at the higher revs—I knew it was wiring-related, but I never found the source of the problem until it blew. “The OE reluctors were used with connectors retrieved from an OE harness, a weakened connection which may cause erratic spark timing when vibration is introduced.  We believe this may have caused detonation flattening the side seals on a rotor face of the first engine.”

Fortunately, Fris was willing to help him install a new motor, and over the winter, the two were able to give the FD another shot at life. “I rebuilt the harness from scratch that time, made sure all the connections were reliable, and upgraded to a Haltech ECU with improved engine safeguards. The tune was and is still managed by Nelson Siverio. He is a wealth of knowledge and the reason I’m interested in tuning as well.”

With the new turbo and an E85 tune, the 13B-REW makes 484 horsepower and 400 lb-ft at the wheels.

Making sure the engine ran well within a set range of parameters was the next goal. “You need to perfect ignition timing—that’s a non-negotiable, and then ensure fueling is appropriate at all times. These engines don’t work well outside of a pretty narrow operational window, so Nelson programmed several failsafes into the Haltech 1500 to keep the engine safe.

For example, if AFRs reach 11.8 at full load—11.2 is ideal—then the ECU triggers limp mode (in several stages) and drops the limiter to 3,000 rpm. I also have several different sensors installed throughout the fuel system to ensure I’m getting more-than-adequate pressure at all times. Monitoring the differential fuel pressure has been the best way to get a sense of what’s happening on the fuel delivery side of things.”

The Haltech did more than make his powerplant dependable—it made it tractable, too. Functions like boost-by-gear and boost-by-throttle position help to limit excessive torque and outline a semi-intuitive power delivery. Despite the big single turbocharger’s rapid onset, Johnson’s grown comfortable with the way the car squirms under power—it’s predictable.

“On the mechanical side of things, I installed an OS Giken 1.5-way differential and had it tuned to suit my torque curve. The lock-up is progressive, and the 295-width tires can handle the power if I’m careful rolling on the throttle. Out of hairpins, I still drive it like a turbo car from the ’80s, though.”

Even the modern Garrett GTX3582R isn’t quite as responsive as he’d like. Well, that may be due to the fact that an old-school HKS cast manifold is causing a bottleneck, but he has more pressing concerns before he can address a slightly lumpy power delivery.

The FD3S’ weakpoint, aside from the obvious engine issues, has been the flimsy five-speed—Johnson’s been through a few. His current answer to this persistent problem is not another h-pattern, but a dual-clutch sourced from an F80 M3. As the factory BMW clutch packs can withstand 600 lb-ft of torque, they should be more than stout enough for his purposes. Additionally, the advantage of seven gears and negligible shift times may help keep him in the meat of the powerband more often—thus solving his problems in slow corners.

It’s a tall order that will require the assistance of some transmission specialists who can mate modern BMW with modern-classic Mazda, but Johnson’s engineering insights and passion for this platform should carry him through the frustrating pioneering period. His commitment to the rotary sports car over the last two decades had made him into more than a mere tinkerer. He’s almost a qualified technician now, and his last forty track days all on the same motor stand as evidence to his understanding of this lovable, finicky oddball.

Buttonwillow: Where to Eat, Where to Stay, What to Avoid

“Just don’t think too much on the drive down,” says Elite Performance’s Gary Yeung.

It’s a long, dull drive to Buttonwillow, and the timing of the drive determines whether the drive is endurable or if it’s agonizing. Plan for construction on I5 if traveling after 8 PM in either direction.

Still, even though it’s the furthest track from San Francisco we visit, Buttonwillow still draws big crowds. Many are willing to make the trip south because Buttonwillow’s flow is unique and always challenging. Fast in places, technical in others, with all sorts of minor nuances that take some time to learn, driving there is never dull. Plus, it’s where most of Southern California’s track drivers benchmark their cars—on the 13CW configuration, anyways. A good time at Buttonwillow carries some weight in the track day community.

Before you can think about setting a quick lap, you have to prepare for difficult weather. The ambient temperature varies wildly, and from March to October, it’s not uncommon to deal with temperatures in excess of 100°F. Do what you can to stay in the shade; the elements will start to slow you down before you notice any decline in performance.

And as the giant tumbleweeds in the vicinity will tell you, it’s not only the stagnant heat you have to worry about. There is usually one good daily gust that can send everything flying, so always tie down your easy-ups.

Most of those who’ve contributed to this article insist that you drive a little further to nearby Bakersfield if you’re insistent on staying the night. Some would rather wake up early and make the long drive south than deal with Buttonwillow’s fleabag hotels. However, you can enjoy a more casual morning if you’re willing to drive to nearby Bakersfield, which boasts better food and a Costco, among other things, to make finding those odds and ends easier.

If you can spend a little more, the garage spots are usually worth the price.

Forty-five to thirty minutes outside of the track, you’ll find some respite from the weather and the iffy lodging outside the track.

Lodging

Motel 6 North

5241 Olive Tree Ct, Bakersfield, CA 93308

Motel 6 Central

350 Oak St, Bakersfield, CA 93304

Bakersfield Marriott

801 Truxtun Ave, Bakersfield, CA 93301

Harris Ranch Resort

24505 W Dorris Ave, Coalinga, CA 93210

Food

Aside from the decent cafe at the track, there are several decent options for a bite.

Taste of India

20687 Tracy Ave, Buttonwillow, CA 93206

Frugatti's (661) 836-2000

600 Coffee Rd, Bakersfield, CA 93309

Hungry Hunter Steakhouse

3580 Rosedale Hwy, Bakersfield, CA 93308

Willow Ranch

27770 Lagoon Dr, Buttonwillow, CA 93206

*Note that this is a good place to fill-up because it’s the last stop before the Lerdo Highway exit for Buttonwillow.

Tita's Pupusería Lonchera (taco truck located near Motel 6 Central)

20645 Tracy Ave, Buttonwillow, CA 93206

The worries of the weather are justifiable, but not something that should keep you from visiting the track. Buttonwillow is not the most accommodating place for a weekend away—hence the reason some choose to drive down the morning of the event, but it is worth the slog. Its flow, complexity, and challenge aren’t rivaled by any other Northern Californian track. If you prepare carefully and stay hydrated, the day spent in the blazing desert sun is well worth it.

Shan's S2000: Hitting the Books

When you’ve had so many formative driving experiences in something as light as a kart, or as purposeful as a Formula SAE, many production cars feel a little cumbersome. This was Shan’s perspective and the impetus to sell his E92 M3 for something responsive, svelte, and raw.

While a college student, Shan was both powertrain lead and test driver on his Formula SAE team. As part of getting the most from their bike-powered spaceframe car, the test drivers – he was one of several – were expected to refine their driving techniques through go-karting. As his own development as a driver dovetailed nicely with his expanding understanding of chassis setup, he developed an unshakable confidence that, years later, would enable a rapid ascent in the world of time attack.

Before he could put himself in a car which would benefit from his years of racing experience, he took a left turn – one that was unpredictable, yet understandable.

He had his foray into time trials with a heavyset production car unlike the other machinery he’d grown accustomed to: an E92 M3. “There were some cars I was considering, but this one was the most versatile.”

Its heft and plush GT-designation left him feeling a little lukewarm, and after five track days, he recognized his need for something with a bit of that single-seater urgency he missed.

First kiss

Rather than go full-180° and buy another spaceframed car, a trailer, and a tow rig, he decided to compromise in the name of practicality. For him, the S2000 was the only fendered car in his price range that had the pointiness he was after. Plus, he didn’t mind hacking one up.

He found an AP2 that, while a little rough around the edges, was a suitable candidate for a track build. A little patina and some missing interior panels didn’t upset him, but the blown Konis certainly made the trek from Los Angeles back to San Francisco less than comfortable. Thankfully, he knows a good chiropractor.

However, those minor annoyances faded when he took the car to Laguna. There, he was reacquainted with all those familiar feelings from his college days — plus a new form of fear.

“I don’t think I’d ever driven something with so much lift-off oversteer before, though that was due to the setup in some part.”

The Honda had teeth; its mystery alignment kept Shan guessing when it would slide. However, even on ancient RS4s and a comically snappy setup, the car was eagerly responding to his subtler inputs. It kept him alert and, with a little time to learn its habits, it raised his confidence.

After adding the first round of track-day bolt-ons – brakes, wider wheels, and a set of forgiving NT01s – he could start exercising his old approach to finding speed. Shan had a few areas of focus:

Ergonomics

Ensuring everything is easily reached was paramount. As he learned from FSAE, the more comfortable one is, the harder they can push. For this reason, he added a very bright shift light directly in his line of sight.

Chassis first

Aside from a Hondata piggyback and a testpipe, the motor would remain stock; the gains would be made in cornering speeds.

No more than necessary

Only parts that had proven to cause a bottleneck or had failed would be replaced. This was done to save, but also to ensure his engineering abilities would be put to good use making the most of what he had.

After accepting the limitations of his Konis, he splurged on a set of JRZ RS Pros. They’d been vetted by his car-crazy colleagues. Raised to an appropriate ride height and aligned correctly, he started putting in the seat time.

The car stayed as it was for some time as Shan delved into the data and refined his technique. “I analyze my laps through RaceStudio and take very detailed setup notes after a session to make sure I'm aware of what's going on, what changes i'm making, how the car responded to those changes, etc.,” he stated.

Complex, but simplifying

When it came time to add some aerodynamic pieces, he used his analytical mind and his engineering ability to make the most of the new alterations.

“My first laps with aero weren’t much faster than my previous best,” he started. “I was still driving the car like I had been before the wings; tentative at corner entry, braking somewhat gently. The aero changed that. I used to worry about oversteering too much at turn-in, but I can throw the car into the corner now. If it needs to scrub some speed, it’ll just understeer.”

He could start changing some parts to make use of the additional aero loading. “Previously I was running a less aggressive compound in the rear because the car was prone to entry oversteer, which would only get worse if the pad compound in the rear could cause momentary locking. With the aero grip, that’s no longer an issue, so I have a high-torque pad at the rear.

Clearly, the right sort of aero helps not only with outright cornering speeds, but stability as well.

Drag bad, grip good

However, this all comes at a price; drag cannot be overlooked in a low-powered car like the S2000. Trimming the wings was vital to find a net improvement in speed, and after using the suggested window for optimal wing angles from 9LivesRacing, he timed every subsequent alteration until he found the fastest settings.

“One thing I did after the first aero day was try to visualize the corner speed increase and drag increase around Laguna. I made plots to understand the behavior better. I could reach out to people with more racing/motorsports experience too, to see if this aligned with what they would consider a car with properly functioning aero, so it was decent validation.”

Shan had to increase his spring rates by 100lb/in to handle the aerodynamic load.

Shan’s taken a studious, resourceful approach to building this gleaming AP2. It might not sport top-shelf parts in every area, but those used have been tweaked and fettled to get the most from them.

An ideal setup is only possible if one has the ability to run the necessary calculations. Shan’s background in racing a clean-sheet kind of car has helped him see what’s vital to speed, and that alone gives him an edge that primo parts alone cannot trump.

He’s clearly passionate about the engineering side of things, too. In fact, he’s used his engineering expertise to build new bits to improve the overall package. They might not be obvious, shiny, or expensive, but, in aggregate, they make a major difference.

“When I have the time, I’ve been using some of the 3D printers at work to build some basic parts to help. For example, I put together some supports to prevent the trunk from flexing at higher speeds.”

Though the car is fast and forgiving, Shan’s still seeking a sharper edge. “The front is much less effective than the rear, and, for now, I just deal with the understeer. I’ll try increasing the rear spring rates to encourage some rotation. It’s not a normal way of dealing with an aero problem, but it might work.”

He’ll find a solution — even if it keeps him in the garage all weekend. For Shan, staring at plots all Sunday to find a few tenths is time well spent.

Parts List

• Sakebomb rear sway bar, Eibach front sway bar

• Bump steer + roll center correction kits

• Recaro Profi SPG driver's seat

• JRZ RS Pro (900lb/in front, 800lb/in rear spring rate)

• Racebred Components front splitter kit

• 9LivesRacing rear wing

• Wilwood Superlite front BBK w/ Carbotech XP12 brake pads all around

• Hasport polyurethane engine and differential mounts

• Maxxis RC1 255/40-17

Andy's NC Miata: How To Make 300 Horsepower In 3 Not-So-Easy Steps

“After five years of ownership, I’ve learned these cars only last when they’re basically stock,” Andy began.

Some of Andy Boskovic’s friend suggested he keep tracking his E92 M3, but it just wasn’t exciting him any longer. “I’d tried a few light cars, and I liked how playful they were,” he recalled. “No matter how much power a car has, if it’s lightweight, it will always be fun,” he said. Plus, the cost of consumables and its heft kept him from relaxing. Careful not to break the bank, he started looking for something svelte, simple, and reliable.

Because of his size and his cost constraints, he bought a mildly prepped third-generation (NC) Mazda Miata. For a third-gen Miata with Megan Racing coilovers, Hotchkis swaybars, and a factory hardtop, a mere five thousand was money well spent.

If there was one unforeseen problem at this point, it was that Andy did not know quite how limited the NC aftermarket was back in 2018, but, thankfully, this car was quick and reliable enough to not need to. The car ran well in stockish trim, and no real changes were necessary for the first two years of tracking.

The factory NC brakes are stellar: Castrol fluid, RB 2-piece rotors, and Hawk DTC-70 pads provided stable, reassuring confidence.

After getting to terms with the car, he could diagnose its few weak points. More confidence on the brakes meant harder laps and more aggressive corner entries, and those highlighted the one glaring handling issue.

Though fun, the car was a little too loose to be truly quick, and this was clearest in the faster corners. “The short wheelbase makes this car oversteer in Riverside,” he started. He first softened the rear bar, then removed it entirely. “I picked up a little understeer when I removed the rear bar, but I gained 1.3 seconds the next session on the same tires,” Andy added.

Another Half-Liter Can’t Hurt

After two years of trouble-free track days, the engine began to knock. Intent on keeping his costs low, he decided to try the 2.5-liter MZR alternative. This particular motor came from a Ford Fusion — a $200 find at his local junkyard that swapped into his car with minimal modification.

Swapping the 2.5 into the NC’s engine bay requires transferring oil pan and valve cover from the 2.0-liter to the 2.5-liter, grinding the front cover engine mount plate to allow the belt to spin without rubbing, and changing one pigtail for camshaft position sensor. Everything else stays the same; the whole harness, ECU, engine mounts work. What’s more, the transmission is direct fit.

It’s a good thing the swap was simple, because the excitement didn’t last long. After just three track days, the engine blew. Andy believes it was a lousy online tune which caused the engine to run too rich. Because he hadn’t installed any A/F meters, he’d been totally unaware of his pistons were getting washed over the first few months.

This setback didn’t deter him. In just a few weeks, Andy grabbed a new motor — one with which he would try a different approach.

Being designed for an SUV, the 2.5 MZR was never really designed to rev. The motor feels genuinely torquey—almost VQ-like—in the midrange, and calling the top-end lackluster would be generous. Extra cubes do help the car feel livelier in slower corners, but the disappointing final few thousand revs warranted a major change — even if the motor was never intended to buzz too high. With a set of Esslinger camshafts and a little headwork to enable 7,500 revs, he extended that top end to a point where things felt S2000-ish.

Another half-liter makes makes life significantly easier.

The 190 horsepower the new lump came along with a few complimentary additions to turn a mild street car into something focused and trailered. Version 2.0 sported a stiff set of Feals, a full cage, and a lot of unsightly bare metal. The stripping process brought the Miata’s weight down to 2,330 pounds, which is not much heavier than a Spec Miata, but with an additional 70 horsepower and 100 lb-ft of torque, those power improvements made the Miata much more versatile.

Compliance is Key in Southern California

The 13K/10K spring rates didn’t suit the bumpier tracks he frequented, so he consulted Karcepts, who tuned the NC cars which ran in the Playboy Cup from 2008-2013, suggested he try a softer setup. They supplied him with some MCS 1-ways, which came along with 10K and 7K springs. The improved compliance netted him a whole second on the same set of tires. Clearly, he was on the right track, though the setup was far from perfect.

In an attempt to try and minimize some of the car’s tendency to oversteer in high-speed corners, Andy cranked the front dampers and left the rears on the softer side. “It rotated when you wanted it to and the rear stayed stable. Still, when the rear finally let go, it was not very progressive.”

“I was never that interested in running aero because I didn’t like that Fast and Furious-look, but I couldn’t accept the snappiness at the rear, so I tried a wing.”

Following the first on-track session with Racebred Component’s 4” front splitter kit and their GT rear wing, Andy forgot entirely about looking like an attention-seeker. The aero bump immediately chopped 2.4 seconds off his previous best at Buttonwillow. Other than adding the wings, nothing else had been done to the car.

The unfortunate byproduct of greater stability in the fast stuff was a smidgen of push. Not so much to keep him from attacking, but just enough to feel the Miata was no longer the playful, adjustable thing it used to be. Cleverly, Andy chopped two holes in his front fenders and topped them with a set of Cockroach Concept louvers. These relieved pressure from the fender wells, improved front downforce, and helped the car regain its natural pointiness — now tempered by the rear wing. It’s extremely neutral in both fast and slow corners, and it’s still soft enough to soak up big bumps.

The performance of the front relative to the rear encouraged Andy to see if he could further strengthen the car at turn-in. With a five-inch splitter and front spats from Racebred, the front end was electric, but more importantly, he could still keep the car balanced aerodynamically, though that required doing something many Miata owners might be hesitant to do.

Trim Fast

Without much torque, Miatas have to avoid as much drag as possible, hence the preference among many owners to run only as much wing angle as necessary. He was conscious of overslowing the car on the straights, but he needed a more neutral balance to push hard. By increasing the angle of attack at the rear wing, he found a confidence-inspiring aero balance that, as he learned, improved the car’s cornering performance enough to incur a little drag.

For someone accustomed to trimming his Miata out as much as necessary, this was a shock finding. “I was losing about three miles an hour on the straights, but the car was so much faster in the corners that I saw a net benefit to this high-downforce configuration.”

Content with the aerodynamic and suspension settings, Andy started on the one area he was reluctant to try. Between a bad tune and his habit of revving the tits off his motors, he went through three engines —one 2.0 and two 2.5s — in the four years he’d had the car. Still, seeing a Mustang or Porsche walk away towards Sunset was a source of real irritation, so he decided to turbocharge his MZR.

Unfortunately, the aftermarket hasn’t provided NC owners with many different turbocharging methods to try. Yes, the MZR has been turbocharged for competition use, but the AER-built motor found in IMSA prototypes and Indy Lights cars is a far cry from the factory 2.5-liter.

Long story short, the turbocharging process has been, as Andy put it, “a world of shit.” The problems with overheating and oil starvation killed one motor quickly, and the current engine, built to maximize torque and keep the revs reasonably low, is still getting the bugs worked out.

However, parking lot tests have demonstrated real grunt, tractability, and promise. With a standalone ECU, a reinforced gear hub in the fragile gearbox, and a smaller wastegate spring, he plans to have a dependable 260 horsepower from 3,500 - 6,500 revs.

“I believe revving the 2.5-liter engine to 7,500 shortens the lifespan to forty track days or so. The turbocharged engine doesn’t need the same revs to make power. If you cap the revs at 6,500 and power around 260, I think it could last. I’m not betting anything on it, though,” he laughed.