Archive for January, 2003

The Race Shop

by Pat Ganahl
Friday, January 24th, 2003

Most companies call it Research and Development. Here at Banks, we call it the Race Shop. I think of it as the toy room.

But calling it the Race Shop is not a bit far-fetched. This shop has not only turned out several true-blood race cars, but it has also produced several world record holders. That is a pregnant statement. The emphasis, here, is on several.

There are plenty of corporations, around the world, that sponsor winning race vehicles. There are a few that actually produce them. But I can’t think of many that have produced as many record-setters as Gale Banks, and this goes back to the days of endurance racing boats, as well as cars.

The most recent, of course, is the Sidewinder Dodge Dakota sport truck, which is officially the World’s Fastest Pickup. This truck—engine, driveline, chassis, body, electricals, everything—was built, tuned, and tested right in the Banks Race Shop by our own in-house crew. The same can be said for the previous World’s Fastest Pickup, the GMC Syclone, which was built in the Banks Race Shop and which topped 210 mph with an unblown V-6 engine in ‘89-’90. And our Banks-built, twin turbo, stock-block 454-powered Trans Am still holds the A/Blown Gas Coupe record at Bonneville at 268+ mph, with a top speed of 283 mph, set way back in 1987. And then there are the multi-record holding Geisler, Vail & Banks ‘53 Studebaker, the Kehoe-McKinney-Banks “Sundowner” ‘68 Corvette, and the amazing 432 mph Al Teague single-engine streamliner. This last multi-record holder was certainly not built in the Banks Race Shop, but Gale Banks is a partner in the effort.

But to call the Race Shop a “toy room” is really highly unfair. It actually is the Research and Development center of Gale Banks Engineering. The nine employees who work there range from draftsmen, to machinists, to engine builders, to expert welders, to sheet metal fabricators, to clay modelers. More than one of them can do all of that. Just about every product produced at Banks, short of electronics, is designed and prototyped in this shop. If it has three dimensions, these guys can very likely make it.

In short, what we call the Race Shop does everything from new product design and prototyping to the wildest special projects (race vehicles or otherwise) that Gale can dream up. When I asked Race Shop Manager John Espino what exactly this department does, his quick reply was, “Rapid prototyping and proof of concepts.” Well put.

Winning Dodge

by Pat Ganahl
Friday, January 17th, 2003

Well, here’s one for you Dodge boys (and girls). Specifically, I’m talking about the members of Turbo Diesel Register, otherwise known as TDR.

The TDR is actually based on a quarterly publication that started in 1993 with a stated purpose to be “an open forum for the exchange of information from the manufacturers to the owners,” and “to give Dodge diesel owners more satisfaction in the ownership of their truck.” The TDR magazine is a collection of regular columns written by a variety of authors, two of whom are John and Polly Holmes. John’s “Ranch Dressing” column refers to their 2JP (John and Polly) Ranch in Silver Springs, NV, about an hour east of Reno, where they raise goats and other animals with exotic “coats” for Polly’s hobby/business of producing “fiber” for spinning into yarns for knitting or weaving. John is retired, but still spends one day a week (Wednesdays) at Carson Dodge in Carson City, doing “special projects.” TDR members know he’s there, and bring in their trucks when they want something “special” done to them.

Polly’s column, “Polly’s Pickup,” is a chatty, feminine-side take on diesel trucking with multi-topics that can range from trailer-towing to her new Dodge Viper (”Snake”), to a recipe for sweet and sour chicken. They’re both gearheads, with a small collection of show-winning vintage cars and trucks. Plus they were both heavy into NHRA drag racing in the ’60s (Polly drove a G/SA ‘67 AMC Marlin). Between them, they’ve had a succession of hard-working diesel Dodge pickups, which tow a variety of trailers to haul animals, hay, and other ranch necessities. And both of them have an insatiable accessory habit. Gotta have those accessories—lots of ‘em!

Last summer they were trying to sell Polly’s ‘97 pickup, but the neighbors wanted John’s ‘00 Quad-Cab instead, so he replaced it with a white 2002, Quad-Cab, 4×4 with an automatic trans. He immediately began to accessorize it with things like custom mudflaps, cab lights, trailer hitch, rear lighting, a custom trans pan and differential covers, and little touches like painting the taillight housings body color. That’s just the short list.

About this time we had contacted TDR to see if we could get some coverage in the magazine on Banks power and braking products for Dodge diesels. They directed us to John and his new 2002. I’ve talked about prototyping new products here at Banks a couple of times, and how we need a guinea pig truck for every model year to fit our new parts to. John’s new truck was just what we needed to test-fit our products on ‘02 Dodges. He was happy to oblige. Installing a complete PowerPack and Banks Brake, with SmartLock, on John’s ‘02 was relatively simple, primarily requiring reworking some of the wiring harness to match changes in the new Dodge’s wire circuits.

But remember the new Computerized Brake Controller (CBC) I told you about on 12/13/02? John’s truck was the guinea pig for that, too. The first prototype CBC was installed on John’s truck, and getting all those little black boxes (including the Ottomind, SmartLock, and CBC, not to mention the ones that come on the truck) talking to each other politely and intelligibly took some doing. But they did. We also did some prototype upgrading to John’s torque converter and automatic transmission, but that will be Banks News for a future Friday.

If you are a TDR member, you read John’s first report on his ‘02 Dodge, including his own modifications and Banks’, in the Nov/Dec/Jan ‘02-’03 issue (#38). With the Banks PowerPack installed and working properly at that point, John reported “it ran like a scalded dog!” The next issue will have a follow-up.

But here’s the punch line for this week’s news. In Polly’s column in that issue, she’ll report on a relatively new TDR event, called Diesels in the Desert. Held last October 25th, this is a Show-N-Shine for turbo-diesel Dodge trucks co-sponsored by the Antelope Valley Chapter of TDR and Hunter Dodge in the high desert town of Lancaster, CA, northeast of Los Angeles. A total of 60 TDR member trucks descended on the dealer’s lot for the 2nd annual event, carrying 180 people, though only 18 tricked-out trucks entered the Show-N-Shine. But some of these trucks were very tricked out. The event also included vendor booths and seminars, and was followed by a barbeque for TDR members.

John and Polly, accompanied by another TDR couple in their own pickup, drove down from northern Nevada the day before, taking the Montgomery Pass over the Sierras and stopping in Bishop for lunch. The next morning John and Polly parked their new 2002 Dodge, complete with Banks PowerPack and Brake and all of John’s owner-installed accessories, in the Show-N-Shine area, and then wandered off to look at the other trucks and enjoy the show. Judging was of the “People’s Choice” variety, with trophies being given for 1st, 2nd, and 3rd place, overall, in the show. When the votes were tallied and the trophies were presented at 2:00, guess who got handed the big one? Yep, John and Polly. You can bet they enjoyed that day. And that’s not at all shabby for a truck that drives on dirt roads on the ranch and traveled hundreds of miles to get to the show. Yes, John, I guess your new Dodge is a “magnificent manure mover,” as you say.

At the Install

by Pat Ganahl
Friday, January 10th, 2003

A couple of weeks ago, when I showed you all the different departments of employees here at Banks Engineering (at the Christmas party), I said I’d tell you more about the Install group in a week or two. Well, make it two.

I guess it should technically be called the Banks Factory Installation Center, but all of us here refer to it simply as Install.

Every day, five days a week, we normally have five to eight trucks and motorhomes in the Install building (or just outside) getting new Banks products—you guessed it—installed. Inside the building there are five lifts and work stations, three of 9,000 pound capacity and two of 15,000 pounds, so they can handle most any kind of pickup or flat bed trucks, gas or diesel. Outside, in a partially enclosed area (which one of the installers referred to as the “Banks motorhome cabana”) are two large drive-on lifts of 27,000 pound capacity each and 20 feet long, so they can handle any type of gasoline motorhome we’ve seen so far. The diesel “pusher” rigs (motorhomes with a diesel engine mounted north-to-south in the rear, behind the rear axle—by far the most common type) are so heavy that they must be worked on on the ground, so there is another stall for them in the “cabana,” next to the two lifts.

Manning these eight work stations are—you guessed it again—eight installers, known here at Banks as technicians. Each is an ASE certified mechanic with considerable experience in the field, usually consisting of some as dealer line mechanics and some in specialty shops. These guys are kept busy by Cliff Hollaway and Jim Ovard, who are the Installation Department Coordinators, who schedule each installation 1-1/2 to 3 weeks in advance. Many installations can be done in one day, even if it’s a complete PowerPack and a Banks Brake (which, it seems, a large number are). Each Banks product or system has a specified installation time, and the customer is charged for this stated time at an hourly rate that is competitive with area auto dealer shop rates. This is a win/win situation for the customer. First, you know ahead of time how much the installation is going to cost, rather than guessing how long it will take. Second, if the technician runs into glitches—and you know how often that happens if you’ve ever turned wrenches yourself—and takes longer than the specified time, you don’t pay extra. (I must point out, however, that if your vehicle has physical problems, such as frozen or sheared exhaust manifold bolts that must be extracted, or if you have made modifications that cause the job to take longer, they will charge you for this extra time, which I think is only fair.) On the other hand, these technicians install these systems on the same vehicles every day, and you can bet they have learned the most efficient methods for doing the job quickly and properly the first time. If they get the job done in less time than specified, you get to go home sooner. That’s win/win, isn’t it?

Contrast this to doing the installation at home, by yourself. No matter how good a mechanic you are, a first-time installation is going to take a lot longer than someone who does it daily. And if you mess anything up, you have to fix it. The Banks Install technicians take every vehicle they work on for a comprehensive test drive when it’s finished. They check the proper operation of such things as the Banks Brake or SmartLock, and they measure such things as manifold pressure and exhaust gas temperature (on turbo diesels) compared to quantities they know should be correct. So they know everything is installed and working correctly before the vehicle is returned to the owner. All Banks products are warranteed for 2 to 5 years (some lifetime), and if any problem arises that is installation-related, you know they’ll take care of it.

The Install guys work from 6:00 to 3:00 daily (I think they’re crazy). But that means that, if your installation can be done in one day, you’ll miss traffic driving in, and you’ll leave before bad traffic in the evening. The waiting room in the Install building is about as nice as most people’s living rooms, with color TV, free coffee, a magazine rack, and drinks and snacks available. It, and the entire install shop, are cleaned daily by the Banks maintenance crew (in fact, their shop is in the Install building, too). But many who are arriving in motorhomes, or pickups towing 5th wheels or other types of travel trailers—from all parts of the country—prefer to park in the quiet dead-end street out front (we refer to it as Camp Banks), to spend the night. We provide water and electrical hookups, and there are nearly always two or three “Campers” out there.

I’ll end with a fun anecdote that typifies a day at Install. Cliff related that one day there were six or eight customers in the waiting room, chatting away. A black diesel pickup with a sprint car-like aluminum wing on the roof pulled up outside, and one of the customers inside, from Virginia, exclaimed, “There’s a truck just like that that I see at home all the time.” When the owner of the truck came in, it turned out that it was the same truck. The two owners lived 40 miles apart in Virginia, and passed each other every day going to work. They became friends in the Install waiting room and, once their Banks parts were installed, caravanned home together—3,000 miles. As Cliff put it, “Every day we get someone from somewhere.” I don’t think I could have put that better myself.