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Autosport machining

Machining a Historic Magnesium RZ5 Gearcase and Clutch Housing for Riley Technologies

Client: Riley Technologies, Mooresville, North Carolina, USA
Project: 1997 Panoz GTR Restoration

Project Overview:

Riley Technologies, a distinguished family-owned business with a rich history in motorsport, selected ShearXL for machining a historic Magnesium RZ5 Gearcase and Clutch Housing. The project involved components for the 1997 Panoz GTR, famously driven by Hollywood movie star Paul Newman and Doc Bundy, which is being restored for historic events and will be preserved at the 3 Dog Garage museum Pennsylvania, USA.

Key Challenges:

  • Lost Pattern Equipment: The original equipment for new castings was missing, posing a significant challenge.
  • Miraculous Discovery: Castings were unexpectedly found in good condition after 25 years in storage at a motorsports company in Huntingdon, Cambridgeshire.

RZ5 Gearcase and Clutch Housing

Machining Process:

 
1. Information Gathering:

  • Reverse Engineering: Accurate data was captured from the sample part and original 1990s drawings, noting several undocumented modifications.
  • Collaboration with Riley Technologies: Ensured all modifications and expectations were understood and met.

2. Machining Execution:

  • Balancing and Datum Establishment: Aligned all machined features with the casting, maintaining aesthetic appeal.
  • 4-Axis Machining Operations: Completed in four stages, ensuring precision with tolerances as tight as 10-20 microns.

3. Safety and Expertise:

  • Handling Magnesium: Our experience and unique coolant allowed for safe machining of Magnesium, reducing fire risk and protecting operators from respiratory hazards.
RZ5 Gearcase and Clutch Housing
RZ5 Gearcase and Clutch Housing
RZ5 Gearcase and Clutch Housing
RZ5 Gearcase and Clutch Housing
RZ5 Gearcase and Clutch Housing

Results

  • Quality Assurance: All three Gearcases and Clutch Housings met the original specifications and were excellent quality.
  • Timely Delivery: The parts were delivered on schedule to Riley Technologies USA.

Client Feedback:

Riley Technologies expressed their satisfaction with the final products, stating, “They look great… we are very happy with the work” Senior Design Engineer. This feedback highlights our commitment to precision and quality, further establishing ShearXL as a reliable partner in the restoration of iconic vehicles.