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Brake Duct Airflow Optimization

21:26
35:53
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At 21:26 in

Dale Earnhardt Inc's Secret Weapon of Restrictor Plate Domination: The "Wind Tunnel Engine"

What happens here

Building on their experience, the team also conducted similar airflow studies for brake ducts. The project became a "battle with the teams" due to the radical differences in brake duct designs (size, shape, concept). The speaker describes building a simple "square box" test apparatus for brake ducts, fitting it with different sized grill screens to represent various intake designs. The objective was to minimize downforce while maximizing cooling efficiency, a critical balance. The initial track testing of these radically new brake ducts saw them fail mid-race, highlighting the complexity and risks of pushing aerodynamic boundaries without sufficient testing.

Goal: Optimize brake duct designs for aerodynamic efficiency and cooling without compromising downforce or causing failure.

Tools and materials

  • Computer — Digital testing (though physical testing was emphasized)
  • Grill screens — Representing different brake duct intake designs
  • Race car — Real-world validation of brake duct designs
  • Small wind tunnel — Cooling testing of radiators
  • Square box apparatus — Testing brake duct designs

What they say

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we did a very similar project with the brake ducks. Um, and after the experience with this, we moved on to the, you know, the break duck deal, and we really made some good headway there. That that was that was totally worth doing. It became a little bit of a battle with the teams on those breakds because they were so radically different in size, shape, and concept that um you know really had to prove it. I think one year, you have to ask Slugger this, but I think the first time I think the first time that they ran were at Louden, this updated brake ducks that you built and like lap two on the 15 car, all the switches for the fans went out and they ran the whole race with no brake fans. And I think he actually finished pretty good. I mean, that's one, you know, I got to ask Slo that one, but I'm pretty sure that that sticks in my head, you know, that they ran the whole race with no brake fans, but they had those brake ducks. That's how much that uh you know and again it was HA ha Morgan I think Chad Walers was running the engineering department at the time you know I was doing all the fab work and we basically took this really cool took a short track car made a big box as big as it would go just a square box and then we clecoed the grill screen on the front and then I made another box that you know we only need to test one side. We did eventually do both, but we made another box that I would fill with this foam and then I had a plug and I just go in and grind it out and we'd make it all whatever, you know, look cool. And then we'd take that plug and put it in a box in winter and then put the smaller, you know, differentiz grill screens over it. And so we had like, oh, a pile of iterations and a pile of iterations. And then we actually had our own little wind tunnel that we built for cooling testing, you know, testing radiators that had a bunch of big, you know, blew some air. And we we did a lot of stuff there with them. And, you know, it was the details I think that made those cars fast. And, you know, that's what's kind of disappointing about racing today, you know, is details. You break the same car. Don't matter. You know, it's like whatever. What were you looking for with the brake ducks? Was it down force or efficiency to cool the down force? downforce, drag, brake efficiency. You know, we were all running those uh we had a we had, you know, the brake duck and the two, you know, the two top hoses. The hose came back and we had this like Y and the Y…

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