dallara F308 User manual

DALLARA F308
Manual F308 CONTENTS VR -03
CAR VIEWS 3
CAR INFO 4
SET-UP 5-6
SUSPENSION Front 7-12
Rear 13-14
DIFFERENTIAL 15-16
DAMPERS 17
RIDE HEIGHT 18
AERODYNAMICS 19-23
COOLING 24-25
UPRIGHT ASSEMBLY 26-27
SYSTEMS Oil 28
Brakes 29
Fuel 30
Extinguishers 31
GEARBOX 32
SAFETY AND UTILITY NOTES 33
TIGHTENING TORQUES 34
CONVERSION TABLE 35
GENERAL AGREEMENT
FIA Homologation document 36 37-40

DALLARA F308
DALLARA AUTOMOBILI IS HAPPY WITH THE CHOICE YOU MADE BUYING
THE DALLARA F308. WE WISH YOU THE VERY BEST IN RACING IT.
Dallara Automobili
Via Provinciale 33
43040 VARANO MELEGARI – PR – ITALY
Telephone [phone]
Belgium office [phone]
design Mr Ferdinando Concari Email [email protected]
technical assistance Mr Jos Claes Email [email protected]
spares Ms David Beck Email [email protected]
On the Dallara web site www.dallara.it you can find useful information about the company,
our people and the factory. It also includes a ‘second hand’ cars service.
Our web site also includes information for customers only, in the restricted area. David
Beck hands out the necessary pass-words.
For any question, advice or idea you might have, please don’t hesitate to contact us.
DALLARA SPARE PARTS DISTRIBUTORS
JAPAN ENGLAND EURO SERIES GERMAN CUP
contact Shiro Matsunaga Martin Stone Tine Schwadtke
Tel [phone] [phone] [phone]
e-mail matsunaga@
lemans.co.jp [email protected] [email protected]

3SIDE & TOP VIEW OF THE F308

GENERAL DIMENSIONS AND SUPPLIER 4
wheelbase 2730 mm
front track 1585 mm
rear track 1535 mm
overall length 4264 mm
overall width 1835 mm [tire-tire front]
overall height 950 mm [roll hoop]
weight 540 kg incl. driver & ballast
front suspension pushrod twin damper system
rear suspension pushrod twin damper system
SUPPLIERS
chassis carbon sandwich with AL/Nomextm honeycomb
bodywork Glass fibre composite with Nomextm honeycomb
composites Delta preg
castings Magnesium World
gearbox Hewland, sequential, six forward gears + reverse
g-box internals Hewland gears and differential
springs Eibach 3“/36mm ID
dampers Koni 2812 bump and rebound adjustable
fuel cell Premier – FT3
extinguisher Lifeline (electric operated)
steering wheel Sparco
quick release SPA-Design
wheels Taneysia 9”front & 10.5”rear
brakes Brembo
battery Deka
seat belts TRW-Sabelt
Honda Mugen XJ6 Mugen & NBE
Mercedes HWA
Nissan Tomei
Volkswagen Spiess
Toyota Tom’s & Torii
Installed
engines
Toyota Piedrafita

5 SET-UPS PER TYRE MAKE
These set-ups consider the complete car with the driver seated in it, ready to race.
FRONT AVON BRIDGESTONE KUMHO DUNLOP
ride height (mm) 18 16 16 15
spring (Lb/in) 900 850 800 900
spring pre-load the basic set-up does not suggest the use of spring pre-load
pushrod length use the pushrod adjuster to set the ride height
roll centre setting std lower std Std
ARB (kg/mm) 35 60 90 35
camber 3,00° 3,50° 3,25° 3,50°
caster-WMP 10,60° 11,00° 10,00° 10,60°
caster-UMP/P-15 12,50° 13,50° 12,50° 13,50°
toe (mm total) 3,00 OUT 3,00 OUT 2,00 OUT 3,00 OUT
REAR
ride height (mm) 35 32 34 35
spring (Lb/in) 800 800 700 800
spring pre-load avoid using rear spring pre-load
pushrod length use the pushrod adjuster to set the ride height
roll centre setting A-1 A-1/F-1 E-2/G-2 A-1
ARB (kg/mm) 60 75 120 90
camber 2,50° 2,25° 2,50° 3,00°
toe 1,00 IN 2,00 IN 1,00 IN 2,00 IN
Differential 70/60 4F 60/80 6F 60/60 4F 60/80 4F
Notes:
¾Ride heights are measured at the axles
¾When using spring pre-load you can lower the front ride height
¾ARB values are those as you can find in the following pages
¾Caster WMP means caster on the suspension with the pushrod mounted on the wishbone
¾Caster UMP/P-15 means caster on the suspension with the pushrod mounted on the upright,
in position P-15 [see later in the manual]
¾Toe is measured at the wheel rim’s, total value means left and right wheels added
¾Differential, see following pages.
Comments:
¾In fast corners aerodynamics (ride heights and wing settings) have more influence on the
balance than in slower corners.
¾In mid-and slow speed corners the weight distribution and the differential settings are the
most important contributors to the balance of the car.
¾Tune the dampers to the chosen springs, not the springs to the dampers.
¾Always pay attention to reach enough high tyre temperatures. No car can reach its limit on
too cold tyres. No car can be reasonably balanced with a significant difference between front
and rear tyre temperatures.
¾Run the car always as low as possible, although without going stiffer on springs for running
lower.

SETUP ADJUSTMENTS 6
Effects of the adjustments on the cars’ set-up.
Positive change in: means:
Height car rises
Toe toe-out
Camber upper part of rim outward
Castor lower part of rim points ahead
FRONT REAR
PUSHROD ADJUSTER
Height change (mm) 4.096 6.413
1TURN Camber change (deg) 1’ 12’
Thread step 24/”R+24/”L=2.12mm 20/”R+24/''L=2.32mm
TOE ADJUSTER (PER WHEEL) Height change -3.37mm
Camber change -18’3”
1TURN toe change (deg) 37’72” -45’27”
thread step 24/”=1.06mm 20/”R+24/”L=2.32mm
CAMBER SPACER +1mm
height change
toe change
17’33”
0.38mm
24’47”
1.87mm
11’= + 1/4Turn
CASTOR ADJUSTER 23° brake calliper=16°
Castor change (deg) 29’41” -36’00”
thread step 24/''=1.06mm 24/''=1.06mm
1TURN height change (mm) -1.427 -0.4
camber change (deg) -4'34” 2'40”
toe change (deg) 0 -1'30”
SPRING PLATFORM
+1TURN thread step (mm) 2 2
height change (mm) 2.29 2.61
WHEEL/SPRING RATIO (vertical) 1.131 1.299
ARB/WHEEL RATIO See table 1.884
ROLL CENTRE HEIGHT Tyre dependent Tyre dependent
¾Spacers to adjust camber are available in the following thickness: FRONT: 1.0, 1.5 and 2.0
mm. REAR: 0.8, 1.0, 1.2, 1.5 and 2.0mm. Combine these to make fine adjustments.
¾Front and rear wheel to spring, front and rear wheel to drop link motion ratios may be
considered as constant for typical wheel travel.
¾For a given ride height the F308 front roll centre is 15mm higher compared the F305.
¾The front roll centre is adjustable by moving the spacer between the upright and the lower
wishbone. More information further in this manual.

7 FRONT SUSPENSION
VERTICAL PRELOAD ADJUSTMENT
Remind there is always some ‘pre-load’ in the damper: typically this is 24-27kg for the
standard Koni damper. This ‘pre-load’ depends on damper make/type and comes mainly
from the internal gas pressure.
In a non pre-load condition, as long as the damper is not fully extended, turning on the
spring platform changes the car ride height (and lowers the gas pressure inside the
damper). When the damper gets fully extended, turning on the platform increases vertical
spring pre-load on the car. We advise though, not to proceed this way, because some
dampers [including Koni] should not be used fully extended. Therefore we advise to use the
droop-stop for limiting rebound travel or applying spring pre-load.
Pre-load in this text is considered to be the necessary force that has to be applied to the
spring to change its length with respect to the static length value.
P = Ks x t x 2
P = pre-load in kg
Ks = spring stiffness in kg/m [(Ks in Lb/in) / 56 = Ks in kg/mm]
T = number of spring platform turns
2 = mm / turn (for standard Dallara Koni damper top)
SETTING PRE-LOAD
¾Mount the damper-spring combination with the spring platform just in contact with
the spring
¾Put the car including the driver on the set-up floor
¾Clear the droop-stop from touching the rocker
¾Adjust ride height with the pushrod adjusters to the desired setting [further correct
for corner weights at this point]
¾Bring the droop-stop in contact with the rocker
¾Now turn the spring platform to achieve the desired pre-load
PUSH ROD ADJUSTER
DROOP STOP
ROCKER

FRONT CASTOR ANGLE SETTING 8
When the car is flat, that is with the same front and rear ride height:
¾WMP: when the upright inclination angle (apparent castor) is +2.10° the castor angle (build
in castor) is 10.60°. The upright reference plane points downwards in forward direction.
¾UMP: when the upright inclination angle (apparent castor) is -2.80° the castor angle (build in
castor) is 13.50°. The upright reference plane points upwards in forward direction.
Drawing shows UMP
CASTOR 13.50°
HORIZONTAL
UPRIGHT
REFERENCE
TRAVEL DIRECTION
When the car has a pitch angle, that is with different front and rear ride height.
For instance, with FRH 15mm and RRH 30mm the pitch angle equals:
[(30-15)/2730] x 57.29 = 0.31°
¾WMP: the upright inclination angle (apparent castor) is 2.10° + 0.31° = 2.41° and the
castor angle (build in castor) becomes 10.60° - 0.31° = 10.29°.
¾UMP: the upright inclination angle (apparent castor) is -2.80° + 0.31° = 2.49° and the
castor angle (build in castor) becomes 13.50° - 0.31° = 13.19°.
REAR
The rear wheel ‘castor’ angle can be measured to check bump steer to be zero. You can measure
the angle on the brake calliper mounting platforms. When the car is flat (front ride height is equal to
rear ride height) and you measure ‘apparent’ castor of 23°, the ‘castor’ angle is 16° and bump steer
is zero.
The castor angle on the rear axle is, other than for the bump steer control, not relevant since the
rear wheels are not turning.

9 FRONT ANTI-ROLL
The drawings shows both motion ratio’s
STIFF
SETTING
SOFT
SETTING
The TABLE below shows the motion ratio’s for all ARB’s and different blades available. Two multiple
position ARB’s are available too.
RATIO = WHEEL/ARB [WHEEL vertical travel / ARB drop link travel]
ADJUSTABLE BLADE ARB
BLADE LENGTH
[mm]
SOFT
SETTING
STIFF
SETTING
PART
ITEM CODE
270 1.187 0.998 30255050
245 1.207 1.012 30555083
221 1.227 1.027 30555031
170 1.272 1.058 T0245066
115 1.324 1.093 30255129
MULTIPLE POSITIONS ARB
1.276 1.059
1.295 1.073
1.315 1.087
1.336 1.102
ARB 5P
1.357 1.118
30555068
1.239 1.031
1.255 1.044
1.272 1.056
1.290 1.069
1.308 1.082
1.326 1.095
ARB 7P
1.345 1.109
30755068
BLADE LENGTH: total blade length in mm , measured between extremities.
SOFT SETTING:
¾use the fixation point close to the rocker axle
¾for a given ARB travel the WHEEL must travel more compared
with the STIFF SETTING
STIFF SETTING:
¾use the fixation point further away from the rocker axle
¾for a given ARB travel the WHEEL will travel less compared with
the SOFT SETTING

FRONT ROLL BAR VALUES 10
¾The values shown below are in kg/mm [daN/mm] at one end of the blade while the other end
is locked.
¾The values below are measured on the ARB isolated from the car. You may use the Motion
Ratio’s from page 5 to calculate the ARB stiffness
at ground .
¾On various ARB’s we suggest not to use the 115mm blade.
ARB BLADE BLADE POSITION
1 2 3 4 5
T-13 solid B-270 3,0 3,1 3,4 3,9 4,0
B-245 3,8 3,9 4,2 4,7 4,8
B-221 5,0 5,1 5,4 5,9 6,0
B-170 10,0 10,2 10,7 11,4 11,6
B-115
T-18x2,5 B-270 5,5 6,0 7,4 9,4 10,0
B-245 6,9 7,4 9,0 11,1 11,8
B-221 9,5 10,1 11,8 14,2 15,0
B-170 21,0 22,2 25,7 30,5 32,0
B-115
T-20x2,0 B-270 6,5 7,1 8,7 10,8 11,5
B-245 8,0 8,6 10,4 12,7 13,5
B-221 11,0 11,8 13,5 17,0 18,0
B-170 24,0 25,3 28,9 33,9 35,5
B-115
T-30x5,0 B-270 8,5 10,7 17,1 25,7 28,5
B-245 11,1 13,8 21,7 32,3 35,8
B-221 16,0 19,4 29,3 42,7 47,0
B-170 41,5 47,8 66,2 91,0 99,0
B-115 187,0 190,0 198,5 210,0 213,8
6 7
5 POINTS ARB 30x2,0 70,0 99,0 150,0 250,0 545,0 - -
7 POINTS ARB 25x2,0 26,5 33.9 44.4 60.3 85.5 129.0 213,1
¾Since there have been some quality problems with the T 13 Solid we replaced this ARB by a
slightly stiffer new ARB, the T-14.5mm Solid. In its softest position with the 270 blade the
stiffness is 4,1kg/mm, in its stiffest position using the 170 blade the stiffness is 16,1kg/mm.
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