2000 MAZDA MIATA

A comprehensive vehicle system build incorporating an automatic-to-manual conversion, Garrett turbocharger integration, custom fabrication, CAD-designed and 3D printed components, braking, safety, lighting and system integration.

VISION

Transform a stock automatic Miata into a distinctive manual, turbocharged performance car while creating a cohesive design across drivetrain, stance, lighting, interior, safety and exterior modifications.

DESIGN

Engineered the automatic-to-manual transmission conversion and designed the integration of a Garrett turbocharger into the aspirated engine.

Planned the vehicle as a complete system rather than a collection of individual modifications, considering how changes to the drivetrain, engine, packaging, braking, safety, lighting, and interior would work together in the finished vehicle.

ENGINEERING CHALLENGES

The manual conversion and turbo systems introduced significant driveline, engine bay packaging, airflow, lubrication, and component clearance constraints.

Solutions included:

• Modifying the driveline to accommodate the manual transmission.
• Packaging the turbocharger and associated components within the limited engine bay.
• Retaining factory air conditioning and power steering despite the additional turbo hardware.
• Managing the airflow from the turbo through the intercooler and into the intake manifold.
• Tuning air/fuel mixture and ignition timing for turbocharged operation.

FABRICATION

Designed and fabricated components required to make the overall system work, including:

• Custom aluminum turbo and intercooler ducting.
• Turbo oil supply and return lines.
• Compact custom air-filter enclosure designed around available engine-bay space.
• CAD-designed and 3D printed stereo mounting components
• CAD-designed and 3D printed auxiliary lighting switch panel.

SYSTEM INTEGRATION

Integrated the new drivetrain and forced-induction systems with vehicle's existing mechanical systems while retaining air conditioning and power steering.

Additional vehicle development included:

• Complete brake system overhaul
• Racing seats
• Five-point harnesses
• Roll bar
• Halo headlights
• Infinite taillights
• Visor lighting
• Underglow

RESULTS

Took Miata from initial concept through design, component sourcing, fabrication, assembly, system integration, tuning, troubleshooting, and final execution. The completed vehicle brought the original design vision together into a distinctive, functional, finished car that was successfully sold.

2006 RAM 1500 TRX4 4WD

A complete vehicle transformation combining powertrain, suspension, steering, braking and electrical work with custom fabrication to create the reliability, stance, proportions and character I envisioned.

VISION

From the beginning, I had a clear vision for the RAM: transform it into a reliable capable truck with stance, proportions and character. Bringing that vision to life required extensive work across the powertrain, suspension, steering, braking and electrical systems, along with custom fabrication and exterior design.

DESIGN

Developed overall direction for the truck around two objectives:

• Mechanical reliability
• Visual proportion

Evaluated wheel size, suspension height, stance and major mechanical systems as parts of a complete vehicle.

EXTERIOR DESIGN & FABRICATION

Sourced and mounted horns to the front of the truck as a distinctive visual element supporting the overall design concept. Designed and fabricated custom mounting brackets to integrate a set of horns into the front of the truck, determining their placement and mounting configuration as part of the overall exterior design.

ENGINEERING CHALLENGES

A persistent taillight failure was tracked to a 34-pin electrical connector located underneath the truck behind the front wheel, where exposure to dirt, water, snow had compromised the connections.

After diagnosing the connector as the source of failure, eliminated the vulnerable connection point and individually soldered the wiring connections, restoring the taillight system and removing the compromised connector from the circuit.

MECHANICAL SYSTEMS

Completed a comprehensive suspension and steering overhaul including:

• Shocks
• Struts
• Ball joints
• Tie-rod ends
• Wheel bearings

Rebuilt the braking system, including:

• Complete primary brake-system rebuild
• Emergency/parking brake-system rebuild
• Replacement of backing plates that had deteriorated from corrosion

POWERTRAIN

Replaced the existing engine with a lower mileage engine to address reliability and extend the life of the truck. The replacement required integrating the powertrain with the truck's existing systems and resolving issues encountered during installation and operation.

RESULT

Transformed the truck into a mechanically reliable, functional vehicle and upgraded the stance and overall proportions. The completed project brought suspension, steering, braking and powertrain systems together as part of a cohesive vehicle.

2007 HARLEY-DAVIDSON SPORTSTER 883 XL

VISION

Create a riding position and overall look that better reflected how I wanted the motorcycle to feel and function, with wider handlebars and a more forward riding position.

DESIGN

Redesigned the rider interface by selecting wider handlebars and relocating the shift and brake controls to a forward-control position.

ENGINEERING CHALLENGES

Changing the location of the handlebars and rider controls altered the distances and routing required for the motorcycle's existing systems. Wiring, cables, and mechanical linkages had to be extended and rerouted while maintaining proper control operation.

SYSTEM INTEGRATION

Integrated the relocated shift and brake controls, wider handlebars, extended wiring, and longer control connections into the existing motorcycle's systems.

REPAIR

Diagnosed and replaced a cracked oil tank to restore proper operation and reliability.

RESULT

Completed the transformation of the rider interface while retaining the motorcycle's functionality, creating the riding position, proportion, and character originally envisioned.

FUNCTIONAL CHRONOMETER

OBJECTIVE

Manufacture and assemble a functional mechanical timekeeping device while developing precision machining skills.

PROCESS

Machined the individual components using manual mill and lathe operations.

TOOLS

• Manual Mill
• Lathe
• Precision Measurement tools

RESULT

Manufactured and assembled a functional chronometer.

PHONE HOLDER

OBJECTIVE

Design and manufacture a functional phone holder from digital model through physical component.

DESIGN

Created the component and final 3D model in SolidWorks.

TOOLS

• SolidWorks
• 3D printing

RESULT

Produced a functional 3D-printed phone holder from the completed CAD design.

CNC-MACHINED COASTER

OBJECTIVE

Translate a digital design into a finished physical component using CNC machining.

PROCESS

Used CNC milling to manufacture the coaster from the completed design.

TOOLS

• CNC Mill
• CNC Machining

RESULT

Produced a finished CNC-machined component while gaining hands-on experience with computer controlled manufacturing.

INJECTION-MOLDED SCREWDRIVER

OBJECTIVE

Produce a functional screwdriver while learning injection molding as a production manufacturing process.

PROCESS

Used injection molding to manufacture the molded component and assembled the finished screwdriver.

TOOLS

• Injection Molding
• Mold & Tooling

RESULT

Produced a functional finished product while gaining hands-on experience with injection-molded component manufacturing.

DROP-FORGED SCREWDRIVER

OBJECTIVE

Produce a functional screwdriver while gaining hands-on experience with drop forging and metal forming processes.

PROCESS

Used drop forging to form the metal component and completed the required finishing and assembly.

TOOLS

• Drop Forging
• Metal Forming
• Finishing Tools

RESULT

Produced a functional finished product using a traditional metal-forming manufacturing process.

MECHANICAL & ELECTRICAL REPAIRS

1994 Police Edition Ford Explorer

Front brakes, pads, rotors

1987 Kawasaki 454 LTD

Carburator rebuild, tuning and balancing

Valve adjustment

Battery

Solidstate Fender Amplifier Head

Diagnosed a power-supply failure, identified failed industrial 6A10 power diodes, and replaced the components to restore operation.