dallara GP2 2008 User manual

GP2
2008
USER MANUAL
Release 1.0
(
7/01/08
)

Dallara Automobili – GP2 user manual 2/87
MAIN VIEWS.....................................................................................................................................................4
GENERAL DIMENSIONS AND SUPPLIERS................................................................................................7
GENERAL AGREEMENT AND WARRANTY................................................................................................7
MILEAGE OF CRITICAL COMPONENTS....................................................................................................8
CRACK CHECKS.......................................................................................................................................8
SAFETY WHEEL TETHERS ...........................................................................................................................9
SET-UP.............................................................................................................................................................10
SUSPENSION PICK-UP POINTS..................................................................................................................12
FRONT SUSPENSION COORDINATES................................................................................................13
REAR SUSPENSION COORDINATES ..................................................................................................13
FRONT ANTI-ROLL BAR (FARB) POINTS COORDINATES.............................................................14
REAR ANTI-ROLL BAR (RARB) POINTS COORDINATES...............................................................14
FRONT ANTIROLL BAR STIFFNESS .........................................................................................................15
STEERING COLUMN POSITIONS...............................................................................................................18
FORWARD POSITION............................................................................................................................18
INTERMEDIATE POSITION ..................................................................................................................18
REARWARD POSITION.........................................................................................................................18
STEERING ASSEMBLY .................................................................................................................................19
CASTOR ...................................................................................................................................................19
MAXIMUN CASTOR REGULATION....................................................................................................19
MINIMUN CASTOR REGULATION .....................................................................................................20
REAR SUSPENSION.......................................................................................................................................21
ROLL CENTER AND ANTISQUAT OPTIONS.....................................................................................21
REAR ANTIROLL BAR STIFFNESS .....................................................................................................22
NOSE FIXING .................................................................................................................................................24
FRONT AND REAR ROCKER MAINTENANCE.........................................................................................25
UPRIGHTS REBUILDING.............................................................................................................................28
FRONT WHEEL BEARING ....................................................................................................................28
FRONT HUB ASSEMBLY..............................................................................................................................28
REAR HUB ASSEMBLY.................................................................................................................................31
DAMPERS........................................................................................................................................................32
DIMENSIONS...........................................................................................................................................32
SETTING UP ............................................................................................................................................34
AERODYNAMICS ...........................................................................................................................................48
DEFINITIONS ..........................................................................................................................................48
FRONT MAINPLANE..............................................................................................................................48
FRONT FLAP ...........................................................................................................................................48
FRONT ENDPLATE ................................................................................................................................49
REAR LOWER MAINPLANE.................................................................................................................49
REAR UPPER BIPLANE .........................................................................................................................49
REAR ENDPLATE...................................................................................................................................49
2008 AERO MANUAL.............................................................................................................................50
1. Introduction .......................................................................................................................................50
2. Rear wing package.............................................................................................................................54
3. Aerodynamic data..............................................................................................................................56
a. Front wing flap adjustment and wicker sensitivity............................................................................56
b. Rear top wing in VERY LOW DOWNFORCE configuration..........................................................57

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c. Rear top wing in LOW DOWNFORCE configuration......................................................................58
d. Rear top wing in MID DOWNFORCE configuration.......................................................................59
e. Rear top wing in HIGH DOWNFORCE configuration.....................................................................61
f. Balanced front and rear wings configurations...................................................................................62
g. Roll angle sensitivity.........................................................................................................................63
h. Constant balance rear top assembly and front flap angles adjustments.............................................65
i. Effect of skirt wear ............................................................................................................................66
BRAKE SYSTEM .............................................................................................................................................67
BREMBO CALIPER:................................................................................................................................68
BREMBO CARBON-CARBON BRAKES:.............................................................................................71
THROTTLE SYSTEM......................................................................................................................................74
THROTTLE PEDAL HYDRAULIC DAMPER.......................................................................................74
The rebound or “Throttle-Off” setting can be adjusted by adding or deleting the calibrated shims, and by
changing the oil density.............................................................................................................................75
The bump or “Throttle –On” damping stiffness can be adjusted by modifying the hole on the valve, which
is 0,8mm; and by changing the oil density.THROTTLE PEDAL HYDRAULIC DAMPER (OPTIONAL)
– OIL FILLING INSTRUCTIONS...........................................................................................................75
THROTTLE PEDAL HYDRAULIC DAMPER (OPTIONAL) – OIL FILLING INSTRUCTIONS ......76
OIL SYSTEM....................................................................................................................................................77
FUEL SYSTEM................................................................................................................................................78
THE FOAM IS NOT ALLOWED ANYMORE!!! ...................................................................................78
COLLECTOR POT MOUNTING PROCEDURE :..................................................................................78
FIRE EXTINGUISHER SYSTEM LAY-OUT................................................................................................79
SAFETY AND UTILITY NOTICES................................................................................................................80
STUD INSTALLATION AND REMOVAL ............................................................................................80
FIRE SYSTEM..........................................................................................................................................80
STEERING:...............................................................................................................................................80
WISHBONES:...........................................................................................................................................80
SUSPENSION...........................................................................................................................................80
SAFETY ISSUES.............................................................................................................................................82
13.1 COCKPIT OPENING :..................................................................................................................82
14.8 SEAT FIXING AND REMOVAL: ...............................................................................................84
TRANSPONDER LOCATION.........................................................................................................................85
SWG & CONVERSION TABLE......................................................................................................................86
SHEET METAL THICKNESS.................................................................................................................86
UNIT CONVERSION TABLE.................................................................................................................86
BASIC INSTRUCTIONS FOR THE USE OF OZ CAST MAG. WHEELS.................................................87

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MAIN VIEWS
Front Track mm 1478
Rear Track mm 1415
Wheelbase mm 3120
Overall Length mm 4867 From nosetip to rear edge of rear endplate
Overall Width mm 1805,8
Overall Height mm 1047 From tub bottom face to telecamera upper surface

Dallara Automobili – GP2 user manual 5/87

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GENERAL DIMENSIONS AND SUPPLIERS
Weight 595 Kg (without driver)
Front suspension Push-rod with torsion bars, twin dampers
Rear suspension Push-rod twin dampers
Chassis Carbon and ZYLON™ sandwich with AL / NOMEX™h/comb
Bodywork Carbon prepreg with NOMEX honeycomb
Composites DALLARA with DELTA TECH materials
Gearbox Gears and differential Mecachrome six ratios plus reverse gear
Springs Front spring Dallara torsion bars - 2” ID REAR
Dampers KONI 2612-010-961 Front
(2 ways adjustable, bump and rebound)
KONI 2822-728&729-475 Rear
(4 ways adjustable, bump and rebound)
Fuel cell PREMIER – FT5
Extinguisher system LIFELINE (electrical operated)
Steering wheel Magneti Marelli design
Steering release system SPA design
Coolers/Exchanger Dallara ( water ) – Dallara ( oil )
Rims O.Z. 13” x 11.75” front – 13” x 13.75” rear
Brake system BREMBO Calipers and master cylinders – Hitco disc & pads
Battery ODISSEY PC545 (Red Top 20)
Seat belt TRW-SABELT
Engine Type Mecachrome V8 – 4000 cc.
GENERAL AGREEMENT AND WARRANTY
Motor racing is not covered by warranty due to the intentional choice of drivers to race
in a dangerous environment
DALLARA indicates that, under normal operating conditions, this model of car, when new, would not
show failure in structural components before it has completed around 10000 Km. This holds true if
necessary maintenance and checks are provided and if the car had no previous accidents.
DALLARA is not responsible for incorrect chassis repairs, if made outside its factory or in centres not
authorized by DALLARA.
Chassis should be checked for structural failure not later than two years after delivery from
DALLARA factory, and after each major accident. After first check or after any major accident it is
mandatory to check the chassis every year in a centre authorized by DALLARA.

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MILEAGE OF CRITICAL COMPONENTS
The following parts must follow a life-mileage program for periodic maintenance / replacement /
refurbishment / dimensional and crack checks.
Listed below are typical expected life ( in kilometres ) to be intended just as a starting reference.
For safety reasons, please contact immediately Dallara if you discover premature wear or problems
SUSPENSION
Suspension w/bones and pushrods 5000 km
Anti Roll Bars and anti roll bar adjustable blades 5000 km
Suspension ball joints 4000 km
Front and rear rocker axial and radial needle bearings 4000 km
Front torsion bars 5000 km
Rocker caps 8000 km
Front hubs 8000 km
Rear hubs 8000 km
Rocker ball joints 2500 km
Front suspension studs 8000 km
Upright 8000 km
STEERING
Steering column and tie rods 5000 km
Steering rack and pinion 8000 km
TUB and BODYWORK
Brake pedal 5000 km
Chassis to Engine installation studs 10000 km
Underwing stays 3000 km
WHEELS, TRANSMISSION and STARTER MOTOR
Brake disc bell (unless fretting occurs) 3000 km
Wheel rims 5000 km
Wheel bearings 5000 km
SYSTEMS
Wiring Loom 10000 km
Water Radiators & Oil coolers (unless fins getting damaged) 10000 km
WING ASSEMBLIES
Front and Rear wing assemblies (including support plates
between nosebox and front wing, and between lower rear
mainplane and rear crashbox). 10000 km
CRACK CHECKS
Routinely perform crack checks on structural parts and after every accident. Among them:
• Rims
• Seat harness brackets
• Brake disc bells
• Wishbones, Toe links, Track rods and Pushrods
• Uprights (visual after every event, with die liquids every 2 events or after shunts).
• Suspension brackets, steering arms and rockers
• Anti roll bars and anti roll bar adjustable blades, and torsion springs.

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SAFETY WHEEL TETHERS
IMPORTANT: Front and rear wheel retation cables, on the chassis side; MUST always be
assembled with the bobbins on the end loops.
FRONT TETHERS – CHASSIS SIDE
FRONT TETHERS – WHEEL SIDE FRONT TETHERS – WHEEL SIDE
REAR TETHERS – WHEEL SIDE

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SET-UP
Suggested Setup
This setup considers the complete car, with all liquids (water, oil, etc), driver and 30 lts of
fuel, ready to race.
BRBR
4444
BRBR
4444
0
--
32 32
20°
80°
Std. Hewland
Nm
Toe 0,15" in 0,15" in
Caster
Camber -0,8 -0,8
A.R.B. Bar External attachments P1
Ø18x4,5
Setting
Damper
Differential
Ramps brake
Ramps power
Plates
Preload
Rear
Front
Damper Packers -mm
Free work space
with car @ ground
15 mm
Setting
Bump stop type
Koni Std 46x10 Koni Std 46x10
Preload 1/2 Turn 1/2 Turn
Springs Rate 900
B.S. length 10 mm
Height Axle
Caster Std. Std.
Camber -2,3 -2,3
Toe 15" out 15" out
A.R.B. Bar
Setting 25x2,5 External attachments P3
Bump stop type Koni rubber
B.S. length 10 mm
Koni rubber
Setting
Free work space
with car @ ground
6mm
Packers -mm
Preload --
Axle
Height
mm mm
24 24
Springs Rate 1200

Dallara Automobili – GP2 user manual 11/87
SETUP ADJUSTMENT
Positive change in: Means:
Ride Height car moves up
Toe toe-out
Camber upper part of rim outward
Castor lower part of rim points ahead
FRONT REAR
PUSHROD ADJUSTER
Ride Height
change
+1 barrel TURN Camber change (deg)
Thread size
3.75mm
0.002°
5/8”UNEF24+5/8”UNEF
24L=2.12mm
5.18mm
0.170°
5/8”UNEF24+5/8”UNEF
24L=2.12mm
TOE ADJUSTER (PER WHEEL)
toe change (deg)
thread step
0.75° (per turn)
1 .06mm-5/16UNF-24 -0.375° (per lmm shim)
CAMBERSHIM +lmm
toe change (deg) 0.30° 0° 0.26° 0°
CASTOR ADJUSTER
Castor change
(deg)
thread step&size
+1TURN Ride height change
camber change
(deg)
toe change (deg)
0.485°
1 .06mm-3/8”UNF-24
-0.84 mm
-0.122°
0.022°
0.606°
1. 27mm- 1/2UNF-20
-0.60 mm
0.05°
0.065°
SPRING PLATFORM
+1TURN thread step (mm)
height change (mm) 1
1.037
WHEEL/DAMPER RATIO (mm/mm) 1.14 1.037
WHEEL/TORSION SPRING RATIO (mm/ α)
1.66
WHEEL/DROP LINK RATIO (roIl) 1.59 1.45
ROLL CENTRE HETGHT [from ground] -0.5 31.9 mm [A2B2C2D2 ]
Spacers to adjust camber are available in the following thickness.
FRONT: 1.0, 1.5 and 2.0 mm
REAR: 0.2, 0.4, 0.5, 0.6, 0.8, 1.0, 1.2, 1.5 and 2.0mm.

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SUSPENSION PICK-UP POINTS
Note:
• Z=0 is the bottom of the monocoque.

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FRONT SUSPENSION COORDINATES
X Y Z
1 163,000 18,000 184,000
2 -320,000 15,000 195,000
3 110,000 150,700 380,000
4 -250,000 178,720 380,000
5 158,000 170,000 380,000
6 -23,000 607,983 380,000
7 -3,500 646,692 188,000
8 54,000 634,926 381,412
9 0,000 732,500 -25,000
10 0,000 715,658 296,359
11 -4,245 600,920 219,327
12 -12,000 125,000 545,000
13 -12,000 110,000 490,000
14 -12,000 20,000 480,000
15 -12,000 130,000 281,895
16 261,000 110,000 490,000
REAR SUSPENSION COORDINATES
X Y Z
1 396,000 131,500 153,000
2 61,000 116,000 143,000
3 442,500 140,000 327,500
4 -62,500 113,500 317,500
5 -62,500 113,500 317,500
6 60,000 554,359 375,021
7 10,000 596,000 159,000
8 -91,031 554,578 372,938
9 0,000 707,500 -45,000
10 0,000 701,917 274,851
11 22,843 540,644 185,367
12 119,134 125,597 369,694
13 157,000 122,615 370,839
14 147,787 39,973 402,562
15 443,430 85,160 384,000
16 157,000 86,778 277,481

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FRONT ANTI-ROLL BAR (FARB) POINTS COORDINATES
X Y Z
17 239,500 0,000 320,000
18 20,500 0,000 325,000
19 239,500 50,000 320,000
20 20,500 50,000 325,000
21 20,950 50,000 484,500
REAR ANTI-ROLL BAR (RARB) POINTS COORDINATES
X Y Z
17 -88,046 0,000 212,755
18 -114,495 0,000 411,285
19 -88,046 79,000 212,755
20 -114,495 65,000 411,285
21 121,500 65,211 392,874

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FRONT ANTIROLL BAR STIFFNESS
There are three different T shaped anti roll bars:
Ø18mm thickness 4,5mm Ø25mm thickness 2,5mm Ø30mm thickness 5mm
The digits in the following table represent the blade positions: 1=full soft, 5=full hard.

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The data refers to the component stiffness: one side of the ARB (one drop link) is considered fixed
and on the other one the stiffness is measured.
The stiffness in this case is F/displ (on one side).
If you need the ARB stiffness @ Ground you have to use what we call AntiSymmetric Model Stiffness
that is 2*component stiffness.
In this case in fact, analyse the roll behaviour of the ARB and you have to consider that both the
sides of the component are moving: under the same force F applied, the displacements will be
displ/2 on one side and -displ/2 on the other side.
The stiffness, as explained, will be 2*component stiffness [F/(displ/2)].
The ARB stiffness @ Ground is AntiSymmetric Model Stiffness/MRarb^2.

Dallara Automobili – GP2 user manual 17/87
Front
MR arb - Droplink D1 (100 mm) 1.590
MR arb - Droplink D2 (55 mm) 1.627
Track 1.465 [m]
P1 P2 P3 P4 P5
Component
Stiffness Component Stiffness Component Stiffness Component Stiffness Component Stiffness
FARB
[kg/mm] [kg/mm] [kg/mm] [kg/mm] [kg/mm]
Ø 18 ø 9 @ Droplink D1 26.0 28.8 32.4 34.1 34.7
Ø 25 ø 20 @ Droplink D1 39.9 47.2 57.4 63.2 65.0
Ø 18 ø 9 @ Droplink D2 87.8 97.7 110.2 116.2 118.1
Ø 25 ø 20 @ Droplink D2 136.7 162.1 200.3 221.2 227.6
Ø 30 ø 20 @ Droplink D2 186.6 238.1 327.7 390.5 410.7
P1 P2 P3 P4 P5
Component
Stiffness
-
AntiSymmetric
Model
Component
Stiffness
-
AntiSymmetric
Model
Component
Stiffness
-
AntiSymmetric
Model
Component
Stiffness
-
AntiSymmetric
Model
Component
Stiffness
-
AntiSymmetric
Model
FARB
[kg/mm] [kg/mm] [kg/mm] [kg/mm] [kg/mm]
Ø 18 ø 9 @ Droplink D1 51.9 57.6 64.8 68.3 69.3
Ø 25 ø 20 @ Droplink D1 79.8 94.3 114.9 126.4 129.9
Ø 18 ø 9 @ Droplink D2 175.5 195.5 220.3 232.5 236.1
Ø 25 ø 20 @ Droplink D2 273.3 324.2 400.6 442.5 455.2
Ø 30 ø 20 @ Droplink D2 373.1 476.2 655.5 781.0 821.3
P1 P2 P3 P4 P5
Stiffness
@ Ground Stiffness @ Ground Stiffness @ Ground Stiffness @ Ground Stiffness @ Ground
FARB
[kg/mm] [kg/mm] [kg/mm] [kg/mm] [kg/mm]
Ø 18 ø 9 @ Droplink D1 20.5 22.8 25.6 27.0 27.4
Ø 25 ø 20 @ Droplink D1 31.6 37.3 45.4 50.0 51.4
Ø 18 ø 9 @ Droplink D2 66.3 73.9 83.2 87.8 89.2
Ø 25 ø 20 @ Droplink D2 103.2 122.5 151.3 167.1 172.0
Ø 30 ø 20 @ Droplink D2 140.9 179.9 247.6 295.0 310.3
P1 P2 P3 P4 P5
Stiffness
@ Ground Stiffness @ Ground Stiffness @ Ground Stiffness @ Ground Stiffness @ Ground
FARB
[kgm/deg] [kgm/deg] [kgm/deg] [kgm/deg] [kgm/deg]
Ø 18 ø 9 @ Droplink D1 384 427 480 506 513
Ø 25 ø 20 @ Droplink D1 591 699 851 936 962
Ø 18 ø 9 @ Droplink D2 1242 1383 1559 1645 1670
Ø 25 ø 20 @ Droplink D2 1934 2294 2834 3130 3220
Ø 30 ø 20 @ Droplink D2 2640 3369 4637 5525 5811

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STEERING COLUMN POSITIONS
FORWARD POSITION
INTERMEDIATE POSITION
REARWARD POSITION

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STEERING ASSEMBLY
Pinion primitive diameter [ mm ] 11.75
Static steering ratio 14.0 steering wheel/wheel
CASTOR
When the car is flat ( front and rear ride height are identical ) and the front upright inclination is
0.00° [APPARENT CASTOR ] the effective castor angle is 5.80° [ BUILT-IN CASTOR ].
With different front to rear ride heights, castor angle changes because of the pitch angle of the car.
For instance, with 20 mm front and 40mm rear ride heights, measured at wheel axis, (wheelbase
is 3120 mm) the pitch angle is 0.367° and castor angles (both apparent and total) are reduced.
Pitch angle : [(40-20)/3120] •57.296 = 0,367°
Total Castor angle : 5.80° - 0,367° = 5.432°
Apparent Castor angle : 0,00° - 0,367° = -0,367°
MAXIMUN CASTOR

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REGULATION
CASTER MAX. = 6.7° (+2 lengthen turns = 2.12 mm)
PUSH ROD = +5 mm (lengthen)
MINIMUN CASTOR REGULATION
CASTER MIN. =3.0° (-6 shorten turns = 6.36 mm)
PUSH ROD = +5 mm (lengthen)
STEER RACK DISPLACEMENT = 28 mm
CAMBER MAX. = -4.80°