Archive for November, 2002

One Camaro to Go

by Pat Ganahl
Friday, November 22nd, 2002

At least one magazine calls them Pro Tourers: a new kind of hot rod with big wheels, very low-profile tires, big brakes, super-tuned chassis, a 5 or 6 speed manual trans, and plenty of horsepower. In other words, a hot rod that drives in something other than a straight line and for distances longer than a quarter mile—much longer.

The ‘68 Camaro under construction in our Race Shop is just such a vehicle. It sits on a chassis jig right next to Rick “Speed” Lefever’s incredible Mercedes 500-SL quad-turbo Pro Mod race car, and Speed splits his shop time working on both vehicles. We’ve been bragging so much lately about our Project Sidewinder Dodge sport truck—the World’s Fastest Pickup, period—that we’ve pretty much overlooked the Camaro project. Heck, it doesn’t even have a name. But it’s pretty incredible, too.

The trouble is, you really have to look to see what all has been done to it. I wouldn’t call this car subtle. But a lot of the modifications are not readily apparent. And Speed is not one to buy a part when he can make it himself. I can’t begin to tell you how much of this car is hand-fabricated.

It began when Gale’s son Andrew acquired a very scruffy ‘68 Camaro a little before he began to drive. It was just a bare body shell at the time, but he and a friend were going to fix it up and make it Andrew’s high school driver. But one thing led to another, and it became a full-on Banks project. Andrew’s been out of high school several years now.

At my house, we call it “we could syndrome,” especially when it comes to car projects with me and my son. You know, “We could do this…and we could do that…”. Some of it gets done, lots doesn’t. When Gale gets going on “We coulds” they can get pretty radical in a hurry. But they usually get carried out—eventually. To say this car is overbuilt is an understatement (just take a look at the rearend housing—and that’s only what you can see on the outside). That’s why it’s been in the project stage quite a while. But this week’s news is that it’s finally on wheels and tires and has a December date set with the paint shop. After paint comes window glass and then upholstery.

The main mechanical component left to build is the engine. It is currently comprised of an iron, 4-bolt main Oldsmobile Rocket small block and a pair of GM Performance splayed valve, symmetrical port aluminum heads. A pair of high-flow, compact Garrett turbos are in place, and they will blow through an electronic fuel injection system as yet to be determined. Same for the crankshaft, so we don’t know exact engine size, but it will be over 400 cubic inches—probably 427. And horsepower numbers anywhere from 800-plus to 1600 have been bandied about, but I’ll bet it’s toward the higher end of that range.

Will it run over 200 mph? We already did that on Mrs. Orcutt’s driveway with much less engine. With a twin-turbo 454 in a stock-bodied Firebird, Gale ran close to 300 mph at Bonneville. But the real beauty of this project car is that it will steer and stop, too. It has ground clearance and creature comforts for cruising cross-country. Which is exactly what it’s intended to do—Pro Tour.

We said it’s slated for the paint shop, but we didn’t mention what color it’s going to be. Come now, do you even have to ask? They’re sending over several samples of red sometime next week so Gale can choose one.

Banks Power for Workhorse

by Pat Ganahl
Friday, November 15th, 2002

At close to 500 cubic inches, the GM 8.1L Vortec in the Workhorse chassis is already the most powerful gasoline motorhome going. So how did the Banks engineers figure out how to get 22% more power out of it? That’s 66 more horsepower and 77 more lb.-ft. of torque. They did it the way we always do—by building prototypes and testing them exhaustively to see what really works best in the real world. That’s why it always takes a little time for us to introduce new products for new vehicles. There are no instant solutions here. But the news this week is that we now have Banks Power available for the 8.1L Vortec in the Workhorse motorhome chassis at both the PowerPack and Stinger levels.

More specifically, Banks uses the same methodology for achieving power increases in nearly all applications: more airflow in, more airflow out. Both the PowerPack and Stinger systems include a Ram-Air intake filter to flow more and cooler air into the engine. It lasts a lifetime and doesn’t need servicing until 50,000 miles (servicing kit included). On the exhaust side, the Banks all-stainless, heat-shielded Dynaflow muffler (no, it doesn’t come from an old Buick; we make them specifically for each application), increases exhaust flow—that is, decreases backpressure—by 65% over stock. Behind that, our mandrel-bent, stainless steel, 4-inch diameter Monster Exhaust slashes backpressure a full 70% over the stock tailpipe. These are impressive numbers that anyone could claim, but we have accurate test data to prove it.

The PowerPack system also includes our stainless steel, mandrel-bent TorqueTube exhaust manifolds with machined 5/8-inch thick flanges for gasketless mounting. If you’ve ever run regular exhaust headers on a vehicle—especially in areas where they salt the roads in winter and especially in hot environments like a motorhome engine housing, you know that they are prone to rusting and warping, which leads to blown gaskets and lots of noise. Our TorqueTubes don’t do that. They’ll last virtually a lifetime. And they’re even designed to protect your spark plug wires (have you priced a set of those lately?).

Being a hot rodder, this last part is what always amazes me. If you take the hot rod approach, with more cam and compression and ignition and carburetion to make more power, you have to expect a decrease in fuel economy, an increase in coolant temperature, such things as a rough idle and noisy exhaust, and general abuse of components in your engine such as bearings, valves, pistons, rings, and cylinder walls. But the Banks approach—increasing airflow—does just the opposite. It actually lowers the engine’s operating temperature, which both increases the density of the air charge for more power and reduces wear and tear on the engine. And it also increases fuel economy. How can you increase power and increase fuel economy at the same time? That seems impossible to someone like me. But Banks does it by increasing the engine’s efficiency. Gasoline engines, in particular, are highly inefficient. They lose power sucking air in, compressing it, and pushing it out (pumping losses); through heat to the coolant; through heat out the exhaust; and to moving parts (friction and inertia). Reduce any of these losses, and you both increase power to the driveshaft and you decrease the amount of fuel needed to make that power. It’s called a win-win situation. And in a big motorhome like a Workhorse, you know you could use some more power—especially when you’re entering an on-ramp or climbing a grade—and you definitely could use some help in the gas mileage department. Come to think of it, the new Banks PowerPack and Stinger systems for the Vortec 8.1L V8 not only last a lifetime, but they’ll also pay for themselves over that lifetime. That sounds like a win-win situation, too.

See Sidewinder Run

by Pat Ganahl
Friday, November 15th, 2002

Seems like hardly a week goes by that we don’t have something new to tell you about Project Sidewinder. This one will be short.

The news is that we had a video crew at Bonneville to capture all the action and sounds surrounding our record attempts, and you can now sample it on our Sidewinder web site. Webmaster note: As this is a very old blog entry, the links have changed. You can now watch a cool video of the Sidewinder Dakota here…

Coupled with footage he had been shooting in our race shop as the truck was being built, Patrick McKinley of our Art Department has spliced together five short clips showing (1) the truck under construction, (2) driving into Bonneville towing its own trailer (not riding on one), (3) activity in the pits, (4) interviews with Gale, driver Don Alexander, and crew chief Sheldon Tackett, and (5) an actual run as seen from the ground, from the air, and inside the cab at speed.

To hear ambient sounds and music, especially for the interviews, you’ll obviously need speakers connected to your computer. If you don’t have a program called Quicktime loaded in your computer, you’ll have to do so. The page with the videos tells you where to click to download it. Then click on each video separately to view it. They’re very short, and they’ll be very small on your screen. But take a look. The one of the truck runing down the salt at 200+ mph—especially if you’re wired for sound—is worth the price of admission.

Patrick has also edited a 23-minute video of all aspects of the Sidewinder and its record-setting runs at Bonneville, culled and spliced from well over 15 hours of footage. It’s really good, and people who’ve seen it have been asking for copies. Word in the opulent and spacious Friday News office is that we are going to make multi-dupes of it and make them available to our customers so you can watch it—full sight and sound—on your home VCR’s. It’s not ready now, but watch this space to see if and when it will be available.

Bob Robe

by Pat Ganahl
Friday, November 8th, 2002

Bob Robe is a glutton for punishment. He’s worked at Gale Banks Engineering longer than any other current employee—this January will mark 25 years.

Seriously, Bob just told me that he couldn’t envision working anywhere else that would afford him the wide range of jobs that he enjoys here. To say that Bob is multitalented is a serious understatement.

His current title is Chief Designer—and that he is. Bob not only makes engineering drawings of all our new products for pattern makers or fabricators to follow, but in most cases he actually designs them as well, following input from Gale. But Bob also puts in time here as a graphic artist, illustrator, architect of sorts, TIG welder, plumber, head porter, machinist, fabricator, assembler—you name it, he can do it. Not only that, but he does it well. Robe’s welds are beautiful. So’s his machining. His routing and bending of hard lines—a very difficult task—is always impeccable. He actually enjoys it. His approach to all of these operations is that of an artist.

Bob started drawing at an early age, encouraged by his mother, an art teacher. Even then he was intrigued by complicated industrial subjects. As a child, Bob says, he used to draw power distribution systems, or power plants, with lots of wires, tubes, circuits, transformers, and towers. A lot of what he draws here today looks similar.

Of course, by the time he got into Junior High he got hooked on hot rods; “strange, unique vehicles,” Bob called them. Then his attention honed in on drag racing. It became his passion. As a “nerdy kid on a bike” he’d hang around Quincy Automotive in Santa Monica to see real race cars, such as the Brisette Brothers’. And of course he drew them, especially dragsters. They were so good that his classmates would actually buy them. “I think I got two dollars for them,” he said. “Maybe five if I colored them.” For these school drawings, Bob used colored pencils. By High School he was using watercolors, and one of his favorite subjects was exotic drag race engines.

Bob also spent time hanging out at the Douglas Aircraft surplus yard, where he gravitated to aircraft fuel lines and plumbing. “Race cars used aircraft plumbing,” Bob noted. At this time he was even considering a career as a commercial plumber—you know, water and sewer pipes.

Before he could drive, Bob talked his father into taking him to the drags at Lions, Fontana, Pomona, San Gabriel, and such places. After he turned 16 his father further abetted Bob’s habit by giving him the ‘56 Chevy wagon he had bought new. With a newer 283 V8 installed, Bob said he kept changing the induction system more to change the looks of the engine than anything else.

After High School Bob spent two years studying (and practicing) Technical Illustration at L.A. Trade Tech, so he is not untrained in his specific field. Next he got a B.A. in Industrial Technology at Cal State L.A., because it stressed more of the hands-on doing rather than engineering theory. “I’m more of an artist than an engineer,” Bob says, flatly. But this is also where Bob learned hand skills such as machining and welding. “I fell in love with TIG welding,” Bob says. “That’s what race cars are built with.” When you see Bob’s welding, it’s obvious he loves doing it.

In the next five or six years after graduation, Bob mixed part-time work as an aircraft illustrator with graduate school at Cal State. Unfortunately, there wasn’t an M.A. program in Industrial Technology, and Bob didn’t want to study Engineering, so he chose Education. He never did complete the M.A., but this is how he met Gale Banks.

Bob still had the ‘56 Chevy wagon, and by this time he had installed an Accel turbocharger kit on it. Gale came to the school to give a lecture on turbocharging, which Bob of course attended. During the talk, Gale mentioned that some jobs were available at his shop, and afterwards he went out to look at Robe’s turbo installation on his Chevy. Bob says he thinks Gale was impressed.

More importantly, Bob inquired about the jobs available at Banks. There were three: Chief Engineer, “Turbo Rigger,” and janitor. Since he didn’t really have an engineering background, Bob applied for the Turbo Rigger position, which was installing the twin turbos and all the other external components on the basic crate motors. At this time, 1978, Banks was building strictly marine engines, and 98% were twin-turboed Big Block Chevies.

Gale hired Bob. But, given his experience, he decided Bob would be Chief Engineer, not Turbo Rigger. The shop was on San Gabriel Blvd. in San Gabriel. There were about 15 employees. And as Chief Engineer, Bob had one employee under him, a machinist. You can imagine that everybody had to wear several hats at Banks at the time. In the beginning Bob primarily did drafting and designing, but also did mock-ups, fitment, new products, and new turbo configurations. In between he did shop designs, floor plans, and architecture, especially after the move to Azusa in 1982 and continual expansion. And if that weren’t enough, in those early days Bob wrote technical copy and ad copy, designed ads and brochures, and did the layouts for the printers. And all this doesn’t even mention welding, machining, tube bending, and wrenching on special projects or race cars, or even things like plumbing the dyno cells.

Now for the fun part—toys. Robe’s got plenty of them. They’re all over his desk. But it’s the one outside his office door that wins the desk toy competition here at Banks. It’s a full-on, ’60s-era, dragster-style blown and injected Chrysler Hemi V8. And it’s just one of three he has.

Actually, it started with a Willys. If you’re into drag cars, you’ve got to love Willyses, because they’re the quintessential Gassers. In fact, drag aficionados are really the only people who like Willyses, both the lean ‘33-’36s and the fat ‘37-’41s. But the ones who love them are passionate about them. The only problem, as Bob readily admits, is that they are so rare, and their owners are so passionate, that most of them stay in a state of constant construction. That’s certainly been the case with Bob’s. He started in 1980 with a ‘35 4-door sedan. He boxed and braced the frame, added coil-over suspension and wheelie bars, and built a twin-turbocharged Buick V6 for power. Next came a Chevy V6 with lots of custom machining and twin-distributor ignition (this was at the tail of a short-lived V6 blip in the high performance field). Somewhere along the line, the ‘35 4-door sedan morphed into a ‘33 coupe, and the boxed stock frame was replaced with a complete custom frame made of 2×3 tubing by Bob.

However, if you know anything about Willys Gassers, you know they’re really supposed to have Chrysler Hemis in them—blown Chrysler Hemis. Bob claims it was an article I did in the December ‘88 issue of Rod & Custom that convinced him his Willys had to have a Hemi, but he quickly became an early Chrysler addict. Again, if you know drag fanatics, you know what I mean. Robe can’t help collecting early Chrysler parts and drag accessories—blowers, injectors, pumps, magnetos, valve covers, you name it. All three of his engines have 6-71 GMC blowers on them. The one in the Willys has two 4-barrel carburetors, but the others always have some sort of fuel injectors. The fun part is that the one outside Bob’s office is always changing. One week it will have a Hilborn 4-port injector and scoop with M/T breadpan valve covers, the next week it’ll have an Enderle bug catcher with Donovan valve covers.

But the thing is that none of these engines has any pistons in them. In all the time he’s had it, the Willys has never moved under it’s own power. Neither of the V6s ever ran. It’s certainly not that Bob’s incapable of finishing this project—not at all. It’s just that, as he says, he’s more of an artist than an engineer. He, very self-admittedly, sees these Chrysler Hemi engines, and the whole Willys, as art objects rather than practical, usable, machines. Personally, I’d like to hear one of those blown Hemis bark and cackle. On the other hand, I fully understand.