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Deposit for New BWR GearSet with new 1-4 ratios and new input shaft, not including final drive. Please contact BWR for build and option costs.
Deposit is non-refundable unless BWR cancels the project. Projected build time is 12-16 weeks.
- Gear Ratios: 1st and 2nd are largely worthless on supercharged cars. Both are too short for both street and track. We've lengthened 1st and 2nd to help put power to the ground in street battles, but kept them in a sweet spot for AutoX. A shorter 4.8:1 KAAZ Final Drive is available if desired. Combined with tweaking 3rd and 4th we've reduced the RPM drops throughout the range to keep the car in the power band at all times and prevent dropping off the Big Cam! Additionally, this closer spread greatly reduces Synchronizer wear as they do less work with tighter ratios. Makes your Lotus feel like a proper race car! We also offer the taller 6th from the Celica GTS. Since 6th is rarely used on the track, this gear drops RPMs on the highway about 500rpm for quieter and better mileage cruising to and from the track!
- Input shaft: The input shaft is a tricky part! It has 1st, 2nd, and reverse molded into the shaft, so it needs to perform well as a shaft AND as gears. Thus we've selected the expensive 300M alloy that adds alot of toughness and max strength to this crucial part. Additionally, we've carefully designed stress-relieving fillets into each gear face where it transitions to the shaft for maximum strength.
- Gear Design 1: We've chosen a low helix larger tooth profile for maximum strength. High angle helix and small tooth profiles are used in street cars for low noise. Straight cut, beefy teeth are used in race cars. We've found the perfect compromise that adds a bit of gear noise that is pretty hard to notice when cruising(let's face it, it ain't a Bentley!), but adds a ton of strength for those track days and autocrosses. No, your car will not whine like a group B rally car, sorry! :)
- Gear Design 2: We've also thickened 1st and 2nd gear on the input shaft and 3rd gear as well. These gears are prone to breakage so where we had room we made the gears wider to add strength!
- Shot-Peen: Shot Peening is a proven process by where hard metal shot is blasted at the surface of the gears like a sand blaster to impart compressive stress. This stress reduces microcrack formation and improves the life of the part AND its maximum strength. When a shaft or gear tooth bends, micro cracks will form where the tensile stress overcomes the surface resilience limits. Once the cracks start they will get worse until part failure. When bending a shot-peened part, the compressive stress on the surface has to be overcome BEFORE it goes into tension. It pre-loads the surface tension the other direction. This process is used extensively by military and aerospace. Our supplier does Mil-spec shot peen on Apache Helicopter blades and gearboxes!
- REM (ISF) Micropolishing: REM is a trade name for ISF - Isotropic Surface Finishing. It is a 2 stage process with chemicals and media to give a mirror-like finish. It is used by ALL serious race teams as it has definite benefits. Firstly, it has less friction which translates to more horsepower and less heat. Secondly, the smoother finish also prevents micro crack formation on the surface which adds reliability. Lastly, it has a synergistic relationship with shot-peening. Shot Peening roughens the surface a bit. With REM-ISF, we can be very aggressive with shot-peen and then smooth the surface with REM, maintaining the benefits of the shot-peening!
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Features
- Made from higher strength Alloys, superior design and heat treatment for maximum strength. Gear ratios optimized for supercharged and turbo cars for the street, AutoX, and track.
- Input shaft design improved with beefier design and superior stress relief. Made from 300M Steel for maximum strength! 300M is used in Desert, Drag, and Rock-Crawling applications. Strong and resilient. Thicker 1st and 2nd for more strength!
- Gears 1-4 designed with lower helix angle and larger tooth profile for maximum strength. This adds a bit of noise vs stock, but very streetable.
- Thicker 3rd gear. Third gear is physically wider in addition to better tooth profile. As the oft-most broken gear in the box, we gave it maximum attention for reliability.
- Superior Alloys and heat treatment. We used the best gear alloy available for gears at any price. Combined with a heat treatment that gives a very hard case finish for wear and cryogenic treatment for maximum martensite transformation, we have maximum performance in every aspect.
- Available Shot-Peen and REM (ISF) Micropolishing processes for more toughness and horsepower. More details in "extended information"
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