Formula 1 represents the pinnacle of motorsport and James Densley along with the team at TDF Limited are breathing new life into retired F1 cars, transforming them back into the ultimate track weapons.👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipJames shares his journey from a car-obsessed child through karting to mechanic at the top levels of motorsport. He recounts his experiences in Formula 3 and then with Mercedes F1, before explaining how TDF Limited was founded and started specialising in restoring and supporting retired F1 cars.The conversation explores the complexities involved in purchasing, restoring, and maintaining historic F1 cars, including the challenges posed by obsolete electronics and sourcing rare components. James emphasises the critical role of modern technologies such as 3D scanning in facilitating these restoration projects.We also discuss the operational and logistical challenges of running historic F1 cars today, the development of the TDF One program to make these cars more accessible, and the technical hurdles of modernizing powertrains while preserving the true essence of Formula 1 racing.It’s unfortunate that these extraordinary machines often face the scrap heap or sit around as expensive ornaments after their brief racing lives. What TDF Limited are achieving by resurrecting these masterpieces and returning them to the track is truly groundbreaking.👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipFollow James here:Instagram: @tdf_limitedYouTube: @tdflimitedWWW: tdf.co.ukTimestamps:0:00 Is a Retired F1 Car the Ultimate Track Toy?4:22 How did you form an interest in cars? 6:34 What’s a race weekend look like in Formula 3?7:59 How do limited slip diffs work?9:19 Tell us about Mercedes F114:00 What is TDF and how did it come to be?18:20 How does TDF Works get a hold of used F1 cars?22:22 Used F1 engines, are they hard to find and get running?27:45 How do we get a trans axel for one of these cars?31:50 What is seamless gear shifting and how does it work?34:41 How do you go about running these cars on old electronics?45:03 How do you source replacement body and aero parts?49:50 Can you put something like a Judd V10 in one of these chassis?52:37 What’s it look like for TDF Works to take a F1 car to the track for the day?58:04 Can you give us an idea of the hydraulic system?59:05 What is TDF One and how does it work?1:02:55 How much of a debate was it to go to a turbo 4 cylinder?1:06:29 How much HP are the genuine F1 cars making compared to TDF One?1:07:59 What is the 4 cylinder engine in the TDF One cars?1:11:03 Are you running a F2 trans axel in the rear?1:12:52 What’s the electronics package and have you added ABS & Traction control?1:15:46 How often do you need to overhaul the engine and gearbox and other parts?1:20:50 How does crack testing on carbon fibre work?1:22:15 How much does a TDF One car cost to run?1:23:57 How many TDF One cars are out there?1:24:44 What’s the build time on one of these cars?1:28:26 Final 3 questions
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1:38:20
143: DIY Motorsport Isn’t Easy But It’s Insanely Rewarding
No matter the stage of a build, most projects reach a point where giving up feels tempting. They demand grit and perseverance—and Karel Silha from Karel S Motorsport’s wild DTM-inspired M4 Time Attack build is no exception.We first spoke to Karel in 2022, and now he’s back to share what it really takes to shake down and test a home-built car of this caliber. Believe it or not, it all started with a toy car that Karel scanned and scaled up using CAD👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipIn this episode, we explore the engineering details behind the build. Karel explains the challenges of mounting a massive aero package capable of generating serious downforce. He highlights the practical difficulties of high-performance engineering in a garage environment.Karel also shares how he’s utilised modern tools like CAD and FEA to optimise the design. We talk through his experience testing on KW Suspension’s seven-post rig—fine-tuning the suspension for low-speed mechanical grip and managing the immense downforce at high speeds.We discuss the complexities of engine management with turbocharging and individual throttle bodies (ITBs), the importance of on track testing versus dyno calibration.Despite the technical challenges and the emotional toll, this episode is far from bleak. Karel’s journey is incredibly inspiring and he’s optimistic that 2025 will finally be the year this insane build shows its true potential. Follow Karel here:Instagram: karel_s_motorsportFacebook: Karel S MotorsportYoutube: karelsmotorsportLinks:Episode 26 with Karel: Building a Tube Frame 1100hp Time Attack WeaponEpisode 75 with Dave Higgins (Aero Dave): The Realities of Driving and Maintaining Your Own F1 Car.Timestamps:0:00 DIY Motorsport Isn’t Easy But It’s Insanely Rewarding4:12 Welcome back, can you give us a quick intro into who you are?6:06 Can you give us a quick overview of the car?12:24 Designing car modifications with serviceability in mind16:40 What engine setup do you have in the car?22:51 How do you go about the first shakedown for a car like this?26:37 How did you go about fixing the initial issues?30:12 What was going on with the wheel speed issue and why do we even need wheel speeds?34:51 Why are you not running ABS?38:15 Wheel speed issues wrapped up.42:29 Were there any other issues in the initial testing? Dry sump issues?49:40 Issues with the fixing points for the splitter and wing? 53:27 What material are you using?56:37 Can the average enthusiast get good results with FEA or do you need to be an Engineer to use it?1:01:25 Did you have any cooling issues?1:07:49 What is the height of the splitter at static ride height?1:11:14 What is a 7 post rig?1:19:44 Are you tuning the car onto bumpstomps to combat aero at high speeds?1:21:46 Where does testing go from here?127:11 How are you going about tuning your engine package? 1:35:11 Were you able to do any gear shift calibration on the dyno? 1:43:00 Will we see you at WTAK in Australia?1:46:35 Final 3 questions
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Field Report: Why Your CAD Designs Don't Work
Designing an elaborate engine block or cylinder head in CAD is one thing, but actually manufacturing that design is another challenge altogether. In this video, we talk with Gerry from Crest CNC about what it takes to turn complex billet and cast designs into realityUse the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipGerry handles CAD design at Crest CNC, creating engine blocks, cylinder heads, and the tooling and fixtures required to manufacture them efficiently. He explains how his early career as a toolmaker led him into CNC machining, CAM programming, and then full-time CAD design. During his time in the UK, he worked at JCB’s engine division, gaining critical experience in engine block and cylinder head design fundamentals.For their cylinder head development, Crest CNC work closely with third-party experts such as Cylinder Head Specialists to optimise port and combustion chamber geometry. They use traditional flow bench testing and 3D scanning to bring these designs into CAD before finalising them for manufacturing.Gerry also discusses design for manufacture considerations, often called DFM. Whether working with billet parts or cast parts, understanding machining limitations, tooling aspect ratios, taper angles, and draft requirements is essential. Design for manufacture ensures that parts are not only functional but also practical and cost-effective to produce.If you want to learn more about how advanced billet and cast engine components go from idea to finished product, or how companies like Crest CNC and Cylinder Head Specialists push high-performance design, this interview is packed with insights you can apply in your own engineering or fabrication projects.
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142: “Composites” aren’t just for high-end motorsport
“Composites” aren’t just expensive and elaborate carbon fibre parts for high-end race teams. It may be easier, more accessible, and cheaper than you think to get started in the composite game.This week on the podcast, we sit down with Keith Peden from Rodin Cars to unravel the world of composites.👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipKeith shares his journey from a childhood passion for cars to becoming a composite specialist in the automotive industry, building parts to the highest level. He emphasizes the importance of hands-on experience and how collaboration between engineering and manufacturing teams is key to success.The conversation explores the properties of different composite materials and their applications in motorsport and automotive design. He discusses various aspects of composites, focusing on the differences between chopped strand mats and woven mats.He also explains resin types, why proper mixing is critical to strength, and how many factors can impact the final product. We discuss different manufacturing methods, from wet layups to prepreg and autoclaves.One of Keith’s big takeaways is that composites don’t always have to mean expensive carbon fibre. For many motorsport and automotive needs, affordable alternatives can deliver excellent results — especially for the home enthusiast.Follow Rodin Cars here: Website: rodin-cars.comInstagram: rodincarsofficialFacebook: Rodin CarsYoutube: RodinCarsTimestamps:0:00 “Composites” aren’t just for high-end motorsport4:00 How did you form an interest in cars?5:33 How do you become qualified in composite manufacturing and what’s your background?16:18 Can you give us an overview of Rodin Cars?27:44 What is your role as Composites Team Lead?31:47 What does the word composites actually mean?33:03 Is a carbon fibre part stronger in compression or tension?35:21 What is carbon fibre and why is it so good for motorsport?38:09 Carbon vs Kevlar vs Fibre glass cost variation?40:42 What is a chopped strand mat?43:05 What is a woven mat?44:44 What is resin?48:49 What does the term prepreg mean?52:55 What is an Autoclave?59:09 Other types of layup methods1:11:55 Downsides of composites parts being repaired1:13:21 How do you add threaded bosses for attachments to a composite part?1:16:24 Final 3 questions
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Field Report: A Clever Solution | 400HP 3-Cylinder G16E-GTS
The Toyota GR Yaris and GR Corolla are already cult favourites, and now they’re about to get even faster.Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipIn this interview, Ben from @artec_performance reveals the 18-month R&D journey behind their fully emissions-compliant bolt-on turbo kit for Toyota’s GR platform. This isn't a generic setup, every component is purpose-built to retain OEM fitment, support factory ECU control, and maintain legal emissions systems. That means you keep your sensors, your catalytic converter, and your conscience clean while chasing 400+ hp.You’ll hear how ARTEC engineered their own turbine housings, compressor covers, and manifold solution to suit Garrett G25 rotating assemblies, why packaging and emissions compliance required more than just off-the-shelf parts, and what makes the G16E-GTS engine one of the most exciting new tuning platforms in years.Whether you’re building a street-legal time attack car or want to keep your road car emissions-friendly while unlocking serious power, this bolt-on system is worth a closer look.
High Performance Academy Presents: Tuned In. A podcast interviewing influential people from around the world at the top of their respected fields. Covering topics such as Tuning, CAD, Performance Engine Building, Automotive/Motorsport Wiring, Data Analysis, Driver Coaching/Training, Motorsport Fabrication and Car Setup.
Netherlands