The Hyper PRO Racer features a state of the art, race bred, Yamaha WR450 cc environmentally friendly 4-stroke engine, 5 speed sequential gear box, 4 wheel cross-vented disc brakes with billet milled 4-pot aluminum brake calipers, Ohlins aluminum bodied race shocks, optimum weight distribution and feather weight design. All this adds up to lap times that compete with the big boys.
The natural enemy of speed is weight. And weight, or the lack thereof, is the Hyper PRO Racers secret. To get ‘light’, we made a smaller vehicle, we eliminated unnecessary components and we made the major component - the chassis - serve multiple functions.
Traditionally the chassis on a racing car serves as a structure for mounting the major components - driver, engine and suspension. Onto the chassis is then attach a plethora of ancillary components such as bodywork, seat, dashboard, fuel tank etc, all held on by multiple gussets, braces and brackets. But once you attach all these parts and the associated brackets and fasteners, you add weight, complexity and more opportunities for mechanical failure.
If you accept that you are just going to attach a part to a chassis via a bracket, then you can skip the design phase completely. Engineering tolerances don’t need to be perfect. You have wiggle room, both literally and figuratively. But if you are going to eliminate these brackets and mount the components directly to the chassis, then the design phase is crucial and it’s critical to manufacture the chassis with absolute precision.
The devil is in the detail
They say the devil is in the detail, and so it is with the Hyper PRO Racer. Hundreds of design hours were spent packaging the major components - driver, engine, wheels - into the smallest possible chassis package.
Each ancillary component was studied to determine whether it was required and then, if it was, how it related to the rest of the vehicle design. It was obvious that if the position and mounting of the ancillary components were designed in conjunction with the chassis, then weight could be saved in the elimination of unnecessary brackets, gussets, etc. To create the Hyper PRO Racer, the design and engineering team have devised ways to eliminate most of these add on mounting or attachment devices.
Solving a design and engineering problem like this required more than an incremental change. It required a breakthrough design. The result is a simple and compact tubular chassis and safety cell. The result is also a work of 'tubular art'.
All the major and ancillary components on the Hyper PRO Racer are mounted directly to the main chassis tubes, eliminating mounting brackets. The bodywork has been rationalized and minimized and mounts directly to the chassis tubes, and as it is non-structural, it is made feather light. The safety cell also does double duty as bodywork. In the weight culling process, some major components such as a front wing and a differential were deemed, for a number of reasons, unnecessary and were eliminated from the design package. Six inch diameter rims and tyres were chosen to reduce weight, aerodynamic drag and importantly, running costs.
So how ‘light’ can you make a real race car, with full-on safety features and big boys performance ?
All up weight without driver, ready to race.
185kg. The lightest racing car in the world.
At the affordable end of the racing world, the space frame chassis is a cost effective design reality, and if well designed, will provide the driver with a very strong safety cell.
However there is a downside. The inside of the traditional fiberglass or aluminum skinned space frame presents a hostile impact environment to the driver in the form of exposed chassis tubes.
Put a compressible safety cell structure on the inside of an exoskeleton chassis. And that’s exactly what the Hyper PRO Racer designers have done.
This breakthrough innovation combines the cost effectiveness of a space frame with the smooth driver friendly internal surfaces of a monocoque design.
The chrome moly chassis features curved main rails for added lateral impact strength and a unique cross brace in the middle of the chassis for immense crush resistance and torsional strength. And in the same way that crash helmet design protects the head, the Hyper PRO Racers seat cell is lined with a ridged compressible foam seat insert. As added protection the seat cell and head restraint incorporate compressible crush pods at all strategic mounting points.
Combine this with the Hyper PRO Racer’s other safety features. Lower body skid rails and intrusion plate, foot and leg protection, a six-point safety harness, an isolated fuel tank, a jointed collapsible steering column, an onboard fire extinguisher and a comprehensive head protection system comprising of front and rear roll bars designed to comply with racing regulations for cars weighing up to 4 times as much, longitudinal intrusion bars (or 'Henry' bars) that help protect the drivers head and ‘flip-up’ to aid driver extraction, and a rear and lateral head restraint enclosure.
It all adds up to built in safety never before seen at the affordable end of motor racing.
The design of the Hyper PRO Racer is based around three major components - driver, engine and tyres. The engine and tyres were primarily chosen on the basis of affordability.
The biggest consumable cost in motor racing is tyres. Tyre costs can break a club level drivers budget. For these drivers it's the difference between racing and staying home for the weekend.
The designers at Hyper Racer thought long and hard about the possibilities and concluded that the only choice was a 6 inch tyre designed for the Superkart category. These tyres are 'state of the art' racing design and are rated to very high speeds. They are readily available world wide and - at under AU$400 per set - are a fraction of the cost of larger tyres as used for example on Formula Ford. They also have the advantage of reducing aerodynamic drag and being very light. And 'light' equals speed.
The choice of engine had to meet a set of criteria which included; manufacture by a mainstream engine supplier, environmentally friendly 4-stroke, state of the art race proven technology, affordable consumables and modest re-build costs.
Yamaha technology was chosen, specifically the 450 WR engine. This engine is fitted with electric start, eliminating the need for a push start buddy.
At club level racing you will inevitably come into track contact with other drivers. Bodywork damage is a fact of life. Again the designers put their thinking caps on. They rationalized and minimized the bodywork. Less bodywork equals light weight. And 'light' equals speed.
As 'real' sponsorship at club level racing is a figment of most peoples imagination, large expanses of panel surface for signage was deemed unnecessary.
It was decided to go for the Café Racer look. Small panels, cheaply and easily replaceable, with enough room for your major sponsors logo - in most cases the name of your own business and an oil or tyre sticker.
To minimise the chance of race damage, the nose cone has been designed with minimal overhang and adequate ground clearance so that excursions into sand traps at unplanned angles of attack should simply result in an uneventful drive back onto the track. In the event of a damaged nose cone, it has been designed as a separate part which can be quickly and cheaply replaced between heats.
Apart from the nose cone and the swing-arm spat, all of the bodywork is mounted high or within the chassis envelope, so a competitor should be able to expect to compete without running up a large bodywork bill.
The designers also addressed the issue of component damage by enclosing almost all the major mechanical components within the confines of the chassis. No more vulnerable radiators in sidepods.
At 185 kg all up, the Hyper PRO Racer is a breeze to tow. Hook it up to your small hatchback, fold the rear seats down and throw in your race gear, a small tool box and a fuel container ......
and go racing.
Karters can now afford to move up to the real deal and a safer world, and car category drivers can get their life and budget under control, by moving across to the financially saner world of the Hyper PRO Racer. Now you can race a real race car, with real performance, on real race tracks, without winning the lottery.
The Hyper PRO Racer. Wash 'n' Race motor sport.