[Bradan]

Bradan 575 project

The following project is based on a 2002 575 in preparation for the Hamptons Rally. It consists of service, performance upgrades, and detailing. All three aspects will be documented in this thread. We have slightly longer than a week to complete this project and deliver the car for Saturday, August 28th. We hope you enjoy following the process.

Stage 1
The car was delivered to us last night. Here are some before images of the vehicle.

 

[Bradan]

Stage 2
The car was shifting into neutral during acceleration which we diagnosed as a worn clutch. We contacted our favorite parts supplier, Ricambi, to overnight us a complete clutch kit. Daniel and Mike came through as always and we had a complete clutch first thing in the morning.

Alex started the process by removing the exhaust system and bumper. By lunch time, the transaxle was removed as well as the old clutch. A close inspection showed heavy wear and glazing. The gearbox oil was changed and a new clutch was installed. Our goal was to have the car on the dyno before the end of the day. By 3 pm, the car was back together and ready for a road test to confirm perfect running order.

 

[Bradan]

Stage 3

The vehicle was moved to our dyno test cell. Strapped down and ready for testing, we brought the engine up to temperature and calibrated the machine. Each power pull was done in 5th gear, the strongest of the 575, because of it's 94:1 ratio. The run started at 45 mph and peaked at 145 mph. Each test was done with the hood closed for induction purposes. Between each run, the hood was left open for 20 minutes to remove heat soak. The 3rd and final run produced a staggering 442 hp and 379 tq. Our pre-test estimates were 400-420 whp. This is a strong motor for sure.

 

[Bradan]

Stage 4

Given the very limited amount of time for this project, the most extensive upgrades we could offer consist of minor intake and exhaust work. So, the vehicle was taken to service once again to have Alex remove the complete exhaust system. After close inspection, it was clear that the exhaust is a major limiting factor in the vehicle's power output.

 

[Bradan]

Stage 5

The mufflers were engineered and constructed this past weekend. The muffler starts out as perforated tubing, sheet metal, and stainless muffler packing. It takes thirteen hours to make a pair from start to finish. Our master fabricator and welder, Ross, starts by bending all the sheet metal to form the case. Then, he assembles the internal chambers. Once fully assembled, the chambers are pressure tested with compressed air to verify there aren't any leaks. Exhaust tip diameter is increased to 3" with a staggered setup. Updates later today...

 

[Bradan]

Stage 7

With tubing diameter increased to 3", we fabricated the complete center section. Resonators have been removed and catalytic converters have been replaced with a two hundred cell metallic race cats. The entire system from the mufflers to the exhaust manifolds are now complete and ready for installation. Tonight and tomorrow will be spent fabricating the exhaust manifolds. All mounting bungs and flanges are being machined overnight.

 

[Bradan]

Manifolds mocked up.

 

[Bradan]

Stage 8
The exhaust manifolds have been sent out for ceramic coated heat insulation. Lead times are not allowing us to have this system mounted for Saturday. Once they return, it will be installed and dyno tested.

 

[Bradan]

Stage 9

To keep peddle feeling consistent and solid, the rubber brake lines were replaced with our stainless steel braided brake line kit and flushed with Motul 600 brake fluid.

 

[Bradan]

Stage 10

Wheels were upgraded to a 19" forged OZ wheel set with Pirelli P zero tires. Tires were filled with nitrogen and OEM TPS sensors were transferred. To prep the wheels for installation, they were cleaned and waxed for easy clean up and finish protection. OEM centercaps were adapted by machining an aluminum adapter ring.

 

[Bradan]

Stage 11

With the maintenance and upgrades finished, the vehicle was handed over to our detailing department. John will now complete our full detail service. This is offered as in individual service and complimentary with all major services.

 

[Bradan]

Stage 12

The vehicle was hand washed and clay barred to remove all surface contamination. It is then transfered to our detail bay to be blown dry with compressed air at 120 psi.

 

[Bradan]

Stage 13
Wheels were removed. All badges, taillights, mesh inserts, and seats are taped in preperation for the paint correction process.

 

[Bradan]

Stage 14

The first stage is a heavy compounding treatment that removes all surface imperfections such as deep scratches and swirl marks. Florescent lighting, halogen bulbs, and a 3M sun gun are used during the process to find all scratches that might not be visible under certain lighting.

Stage 15
After compounding, the paint is cleaned with an alcohol/water mixture to remove all compound residue. The vehicle is then inspected to verify all imperfections are removed. With this now complete, the finish is polished back to a bright reflective shine.

 

[Bradan]

Stage 16

To further enhance the finish, John switched from a rotary wheel to a cyclo dual orbital machine and applied a finishing gloss to achieve that deep wet look.

 

[Bradan]

More. Polishing the horse.

 

[Bradan]

Stage 17

With the paint corrected, it is now sealed with a carnauba hand wax. John meticulously covers all paint surfaces for a long lasting finish.

 

[Bradan]

Stage 18
The exterior is reassembled, inspected, and buffed by hand using a gloss enhancer spray.

 

[Bradan]

Stage 19
With the exterior now complete, John moved to the interior. The general condition of the interior was great. To prevent sun damage, the leather will be cleaned and conditioned and all carbon fiber trim will be individually protected from fading with the same wax used on the exterior.

 

[Bradan]

Stage 20
The carpet is cleaned and conditioned by hand and then striped to align all carpet fibers.