ASTRONAUTS RICK STURCKOW AND JERRY ROSS GO FOR A RIDE IN THE MACPHERSON 4WD TROPHY TRUCK - CIRCA 1998

So my good friend Rick Sturckow from Cal Poly (and one of the prime team members from the previously shown 1981 Riverside World Championship Class 7 win in our Cal Poly Toyota with Roger Mears at the wheel) went on to be a Marine Corps F-18 pilot - flew many missions in Afghanistan - Top Gun - became a test pilot -flew over 60 different types of aircraft - and eventually ... if you are one of the best at all of that ... you become an astronaut! Colonel Fredrick W. Sturckow flew 2 shuttle missions as a pilot and 2 as the Commander helping to build the International Space Station. After NASA he went on to be a flight test pilot for Virgin Galactic ... I could go on! So one day we realized he would be flying in some specialists to Edwards Air Force Base for the day and had some time to kill ... and we happened to be testing with Team MacPherson that week out in nearby Barstow. So he and fellow astronaut Jerry Ross (then already with 7 space shuttle flights to his name) grabbed a car after they landed and headed out to the test area for a ride with Jeff Lewis in the MacPherson Trophy Truck ... still in their NASA jumpsuits! As much as they enjoyed the rides ... the MacPherson crew enjoyed their stories of how rocket launch G's kick you in the butt while heading into space! It was some awesome bench racing!

Bryan Kudela, Rick Sturckow, Jeff Lewis, and Jerry Ross.

Bryan Kudela, Rick Sturckow, Jeff Lewis, and Jerry Ross.

THE FIRST LANTERNMARK (LIGHT RACING) CAD WORKSTATION - CIRCA 1994

The first CAD software we used was Ashlar Vellum (3D wireframe) installed on an Apple Power Macintosh 8600/200. This early audio/visual capable computer could record voice over live video of what you had on-screen, and we would record design reviews while rolling around the 3D model on the computer. LR-24 was our first truck (3 Baldwin Trophy Trucks) designed on the computer rather than the drawing board. The image on both screens in the photo is from the LR-26 (Team MacPherson Big Mac Trophy Truck) CAD model. In those days, If memory serves me correctly, that Mac computer set-up was around $4500, that high quality laser printer (in the corner) was $5000 and the Mutoh Pen & Pencil capable plotter (left) for our full size prints was like $7000! Some things have actually gotten less expensive!

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NOTES FROM THE LIGHT RACING LR-2 CLASS 7 CHEVY S-10 CIRCA 1987 - DRIVER LARRY RAGLAND

CHASSIS (SIDE VIEW) - Drawn by hand in half scale - we needed 3 large drafting tables and would put a different view on each table (front - side - top). The grid lines were critical since you had to transfer a lot of dimensions between drawings. The extra cabs were relatively new back then and we loved the ability to scootch that driver back and give them some more room. Note also the high point on the roll cage over the rear axle. I had proposed (to GM) designing our own custom length shocks which would have required a high mounting point. That cost add was around $100 grand (back then) for engineering and building custom shocks and Bilstein was paying $50 K to use their parts ... a $150 K swing in the budget! So ... GM made us stay with the Bilsteins and that drove the design of the "Grasshopper" rear rocker, allowing 21" of travel with modified off-the-shelf 14" travel shocks (the longest available at the time). The Class 7 rules stated "No remote mounted shocks"! So ... we made sure one end was attached to the axle.

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CHASSIS (TOP VIEW) - The detail drawings for the shop to build the frame and all of the components were all done in full scale. This allowed the fabricators to literally trace out some of the plates that needed to be cut by hand on a band saw ... pre-laser cutting days! These full vehicle half scale drawings were used primarily for design layouts.

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COIL ADJUSTER NUTS - Hand drawn

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REAR LEAF SPRING SHACKLES - The SCORE Class 7 rules back in the day required the vehicle to be supported by leaf springs (stock length) in the rear per the production truck suspension type. However there was no rule yet that said you couldn't have other control links! LR-2 used a complete 4 link system for superior axle location control for the 21" of rear travel. Since the axle is normally located by the leaf spring system ... the added 4-Link system would be redundant and result in competing locational forces. This was solved by using articulating tension shackles at both the front and rear leaf spring eyes which greatly reduced any conflicting load paths. This allowed the weight of the vehicle to be suspended by the leaf springs, but the suspension not precisely located by the leaf springs. Note also the 4130 sheetmetal double thin-wall outboard shackle mounts.

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REAR LEAF SPRING UPPER SPRING CLAMP - Modeled and drawn by hand in 2D and made from 7075-T6, this lightweight, multi-function mount on the rear of the Larry Ragland Chevrolet S10 accommodated four U-Bolt nuts, three lower shock mount bolts, and one rocker drive link bolt.

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FRONT COIL SPRING STACK COMBINATION CHART - CIRCA 1988

All of the 2 stack combos were mapped out in the chart shown here for easy reference out on the track during testing.

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SHEET METAL TRUSSED REAR AXLE HOUSING

When is the first time you saw a 4130 Chromoly sheet metal trussed rear axle housing? This high modulus light weight construction used largely .063" and .050" sheet, flared holes, and capped double thin wall - double shear link mounts. Used on the Chevy S-10 Class 7 driven by Larry Ragland. This truck won it's first race (1987 SCORE/Riverside Off-Road World Championships), was SCORE/HDRA Class 7 champion in it's first season, won the 1988 SCORE/Riverside Off-Road Class 7 Championship, and finished every race mile of every race entered as a GM Chevy factory entry.

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SPHERICAL ROD END RECEIVER DESIGN - CIRCA 1990

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Also referred to as cinch clamps - here is one of our original hand drawn designs from 30 years ago, which evolved into our current line of light weight Spherical Rod End Receivers. In the early off-road racing era, these fabrication elements were conceived in order to eliminate rotation of the spherical rod ends in links and control arms where loosening of the typical jam nut occurred. Our cinch clamps are made from 4140 N chromoly and utilize stress reducing routed corner details for the lightest strength per weight and highest quality available.

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PPI TOYOTA LOWER CONTROL ARM/TORSION BAR DESIGN - CIRCA 1984

While chief engineer Carroll Smith was traveling the world at road races I was able to engineer and detail design the torsion bar/subframe system for the 1984 PPI Toyotas. The 3-stage torsion bar system used 3 bars in series ... one longer main bar, and two shorter segments. All segments could get swapped out for varying primary, secondary, and tertiary rates. Adjustable stops at each bar transition allowed tuning of where each progressive rate began in the travel. The extra-long total bar length was accommodated by running the torsion bar through the LCA pivots attaching to the anchor at the front of the control arm. Naturally, all of the T-bars were hollow for the lightest weight design! Did you know that a hollow torsion bar is one of the most weight efficient steel spring designs? A coil spring is essentially a solid torsion bar winding up in a less efficient manner. In the 1984 Toyotas the rules dictated torsion bars due to the stock configuration, but I prefer them anyway when using a steel spring due to their mass efficiency as well as the ability to place the relatively heavy steel spring mass at the very bottom of the vehicle.

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GM Defense Delivers First Infantry Squad Vehicle to U.S. Army

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MILFORD, Mich. — GM Defense LLC, a subsidiary of General Motors, is celebrating the first delivery of the Infantry Squad Vehicle (ISV) – a light and agile all-terrain troop carrier intended to transport a nine-Soldier infantry squad and their equipment – to the U.S. Army as part of a $214.3 million contract awarded in June. GM Defense will manufacture 649 ISVs and will support the production of up to 2,065 vehicles with additional authorization over eight years. This is the first major award and delivery for GM Defense since the subsidiary was reestablished by its parent company in 2017.

The ISV is based off the award-winning Chevrolet Colorado ZR2 midsize truck architecture and leverages 90 percent proven commercial-off-the-shelf (COTS) parts, including Chevrolet Performance race components. The 5,000-pound ISV was uniquely engineered to fulfill military requirements and designed to provide rapid ground mobility. The expeditionary ISV is light enough to be sling loaded from a UH-60 Blackhawk helicopter and compact enough to fit inside a CH-47 Chinook helicopter for air transportability. The COTS parts, combined with the ISV’s innovative Rollover Protection System, will provide agile transportability on the battlefield to support mission success.

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“One hundred and twenty days from contract award to delivery is a significant milestone, and I am very proud of the team for this accomplishment,” said David Albritton, president of GM Defense. “We’re leveraging General Motors’ engineering prowess and immense manufacturing capabilities to bring transformative solutions to the military vehicle market. Our initial success with the ISV shows our commitment to our customer and highlights our unique right to win in the military mobility market.”

“The value we bring to our Army customer is our willingness to listen and adapt,” said Mark Dickens, GM Defense chief engineer. “During Soldier testing, the feedback we received was paramount in delivering a vehicle that met Soldiers’ needs, while maximizing safety and performance and taking their comfort into consideration. The production ISV we’re delivering today is an evolution from our original prototype design, and it’s certainly a vehicle that is a source of pride for the team.”

GM Defense has a teaming agreement with Ricardo Defense, which will lead the Integrated Product Support for the ISV, including technical manual development, new equipment training, provisioning, total package fielding and field service support.

“The success of the ISV program within 120 days is a true testament to the hard work and determination of a great partnership between GM Defense and Ricardo Defense,” said Chet Gryczan, president of Ricardo Defense. “Ricardo Defense is proud to be leading the creation and integration of critical ISV logistics products to ensure a successful transition of the ISV to the Army’s inventory.”

GM Defense is driving the future of military mobility by leveraging the best-in-class capabilities of General Motors for unmatched innovation, proven performance and breakthrough life-cycle economics. The ISV will bring world-class manufacturing efficiencies, ease of maintenance and a well-established global supply chain to the U.S. Army.

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Stay tuned for future updates on www.GMDefenseLLC.com.

GM Defense LLC delivers integrated vehicles, power & propulsion, and mobility & autonomy solutions to global defense, security, and government markets. The exceptional reliability of GM Defense’s technologies results from decades of proven performance and billions of dollars spent in independent research and development by its parent, General Motors, a world leader in global design, engineering and manufacturing capabilities.

Originally Published: https://media.gm.com/media/us/en/gm/home.detail.html/content/Pages/news/us/en/2020/oct/1027-gmdefense.html

RIVERSIDE OFF-ROAD WORLD CHAMPIONSHIPS - CIRCA 1981

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The first of 6 SCORE Riverside Off-Road World Championships in Class 7 that we were involved with. In 1981 we were a part of the student group of the Society of Automotive Engineers at Cal Poly SLO when we convinced Roger Mears to drive our student built Toyota Hilux in the famous venue. Originally slated to drive the Jim Conner Olympia sponsored Nissan (Datsun back then?), and after an initial test run, Roger agreed to drive our Cal Poly truck in the race. Jeff MacPherson then took over his ride in the Oly Datsun, and ironically was the only truck to beat Roger into the first turn after the traditional land rush start. However Roger wasted no time in overtaking the leader in the S-turns and then led the rest of the race for the victory!

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The Cal Poly Toyota in the Mears Gang pits at the 1981 SCORE Riverside Off-Road World Championships. In those pre-wrap days, most of the graphics were air brushed on the vehicle for each race as needed. Our student built motor was to go up against the other competitors professionally built motors. We spent countless pre-race hours and all-nighters in Roger's shop and in the race pits working out a few issues leading up to the race ... but come race time, it didn't miss a beat and all the hard work paid off!

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For the 1981 Score Riverside Off-Road World Championships we built a custom short course fuel cell for our Cal Poly Toyota Hilux that weighed much less than our regular desert race cell. In those days, everyone in the truck classes would simply run their desert trucks in the occasional short course races during the busy desert race season. Not many competitors went through the trouble that we did to make our truck lighter: notice also the aluminum rear bumper and the holes in a lot of the brackets ... not common at that time. The relatively heavy trophy in this photo was not there during the race.

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I remember years later Roger told us it was still one of his favorite wins ... I believe because he made it happen and made a huge impression on an underdog bunch of hardworking college kids who were overjoyed at the outcome and stamped forever with the impression of the experience. Jack Auld, Mario Santellan, Al Bodey, and Bryan Kudela (Lanternmark Industries) all ended up working in the off-road space for Cal Wells at Precision Preparation Inc ... and onward with many others. Rick Sturckow went on to become a pilot for the Marines, a top test pilot, and eventually flew 4 space shuttle missions, 2 as a Pilot and then 2 as the Commander. And some of you may recognize Alan Roach as the founder of Baja Designs ... all from that era at Cal Poly ... to name a few. HAPPY CAMPERS to say the least!

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GM Defense Awarded $214 Million U.S. Army Infantry Squad Vehicle (ISV) Contract

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GM Defense LLC was awarded a $214 million firm-fixed-price contract by the U.S. Army for acquisition of the Infantry Squad Vehicle (ISV). The contract also includes installation kits, ancillary hardware and logistical support. The U.S. Army Contracting Command (ACC) at Detroit Arsenal, Michigan, is the contracting activity (W56HZV-20-D-0066).

Work locations and funding will be determined with each order, with an estimated completion date of June 24, 2028.

The U.S Department of Defense has also announced another contract, worth $8.58 million, for initial delivery of Infantry Squad Vehicles and integrated product support. Work locations and funding for this contract will also be determined with each order, with an estimated completion date of June 24, 2021.

GM Defense ISV

GM Defense’s ISV is based on the Chevrolet Colorado midsize truck architecture and its ZR2 and ZR2 Bison variants, supplemented with both custom and commercially available parts proven by Chevy Performance engineering in more than 10,000 miles of punishing off-road development and desert racing in the Best in the Desert Racing series.

Applied to ISV, Colorado’s architecture undergirds an occupant and cargo superstructure powered by a 186-horsepower, 2.8L diesel powerplant, and six-speed automatic transmission.

GM’s solution to the Army’s next-generation transportation challenge features 70 percent commercial-off-the-shelf (COTS) components, including high-performance parts developed and proven by Chevy Performance engineering such as long-travel Multimatic DSSV dampers, long-travel rear leaf springs, jounce shocks, front upper control arms, steel driveshaft, underbody skid plates and ball-spline half shafts. Most of these parts are available either on the Colorado ZR2 Bison or as Chevrolet Performance race components.

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U.S. Army Infantry Squad Vehicle (ISV) Program

Through the Infantry Squad Vehicle (ISV) program, the U.S. Army is seeking a lightweight expeditionary all-terrain vehicle that is essential to increase speed in combat and provide the ability to be transported by helicopter into austere locations.

The ISV must be light enough to be sling-loaded from a UH-60 Blackhawk helicopter, compact enough to fit inside a CH-47 Chinook helicopter and versatile enough to carry up to nine soldiers and all of their gear at highway speeds on pavement and off-road under extreme conditions with a payload capacity of 5,000 lbs. A full Production Specification is expected to be released with the RFP.

The ISV will provide enhanced tactical mobility for Army Infantry Brigade Combat Teams (IBCT) to move quickly around the battlefield, including the ability to execute medium distance insertion operations, providing commanders greater freedom of movement and freedom of action.

Other than the GM Defense’s ISV proposal, the other two proposals for the program were Oshkosh Defense-Flyer ISV and SAIC-Polaris DAGOR.

Author: Arun Mathew

Originally Published: https://defpost.com/gm-defense-awarded-214-million-u-s-army-infantry-squad-vehicle-isv-contract/#:~:text=GM%20Defense%20LLC%20was%20awarded,Infantry%20Squad%20Vehicle%20(ISV).&text=Work%20locations%20and%20funding%20for,date%20of%20June%2024%2C%202021.

Introducing the Infantry Squad Vehicle from GM Defense.

Following recent field tests at Fort Bragg, North Carolina, the US Army selected GM Defense’s Infantry Squad Vehicle for further assessment, contracting to build two more prototypes and for testing beginning in fall 2019.

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GM Defense’s ISV is based on the award-winning Chevrolet Colorado midsize truck architecture and its ZR2 and ZR2 Bison variants. Supplemented with both custom and commercially available parts, the underlying architecture has been proven under duress by Chevy Performance engineering over more than 10,000 miles of punishing off-road development and desert racing in the Best in the Desert Racing series.

Applied to ISV, the Colorado’s architecture undergirds an occupant and cargo superstructure powered by a 186-horsepower, 2.8L diesel powerplant and six-speed automatic transmission. Some 70 percent of ISV parts are provent commercial-off-the-shelf components.

To meet Army requirements, the ISV must be light enough to be sling-loaded from a UH-60 Blackhawk helicopter, compact enough to fit inside a CH-47 Chinook helicopter and versatile enough to carry up to nine soldiers and all of their gear at highway speeds, both on pavement and off-road under extreme conditions. The Army plans to acquire approximately 650 ISVs beginning as soon as 2020.

GM’s solution includes high-performance parts developed and proven by Chevy Performance engineering such as long-travel Multimatic DSSV dampers, long-travel rear leaf springs, jounce shocks, front upper control arms, steel driveshaft, underbody skid plates and ball-spline half shafts.

 “Our ISV entry is a fully-integrated platform that leverages decades of GM’s engineering, manufacturing and quality expertise at scale to provide the most cost-efficient, reliable and effective answer possible to meet and exceed the Army’s demanding requirements,” said GM Defense President David Albritton. “We’re very proud of the opportunity to move forward in this competition and continue our development of a vehicle that will enable Army units to move around the battlefield with greater ease and reliability.”

ISV’s Multimatic Dynamic Suspensions Spool Valve (DSSV) dampers use precision spool valve technology for maximum predictability, accuracy and repeatability, minimizing jolts to passengers and delivering the ultimate in wheel and vehicle control. Underbody skid plates protect the front suspension, engine, transfer case, fuel tank, rear differential and rear shock mount. Advanced software and calibration ensure optimal performance for the engine, transmission, transfer case, locking front and rear differentials and electronically assisted power steering.

Article & Image courtesy of GM Defense LLC

Originally published: https://www.gmdefensellc.com/site/us/en/gm-defense/home/news/2019/infantry-squad-vehicle-prototype-testing.html

TECHNICAL: LRG 4140 vs 4130

FAQ: Why does LANTERNMARK use 4140 N vs. 4130 N for most of their Fab Elements?

ANSWER: 4140 offers the potential to create a much stronger part, and does not preclude or detract from the use of 4130 in a combined weldment. Here’s why:

The chromium-molybdenum (Chromoly) alloys AISI/SAE 4130 and 4140 are considered Ultrahigh-Strength Steels. Both are medium-carbon (0.30-0.60 % carbon) low-alloy steels. 4140 is similar in composition to 4130 except for the higher carbon content. The “30” in 4130 represents the carbon content by % of weight (0.28-0.33 % for 4130 vs 0.38-0.43 % for 4140).

Because of its higher carbon content, 4140 steel has greater hardenability and strength than does 4130. Due to its deeper hardening characteristics, 4140 is generally a better material to be used for billet machined components where discontinuities and variations in section, as well as thicker overall sections, are present. Because of this, 4140 is typically more readily available and more cost efficient in bar and plate forms, while 4130 is more commonly obtained in tubing and sheet forms. Also, if you are not heat treating afterwards, the original machined 4140 steel fabrication element which we are offering, has a better chance of being through hardened (to the normalized level) when you get it than if we were using 4130 steel.

Regarding relative strengths, the 4130 suspension component is typically heat treated to the low 30’s on the Rockwell C scale, resulting in tensile strengths in the 140-150 ksi range. The 4140 steel suspension component will be heat treated to RC numbers in the low or even mid 40’s, which equates to strengths in the 185-210 ksi range. Therefore 4140 offers the potential to create a much stronger part if combined with other similar carbon content chromoly alloys such as other 4140 pieces, or parts made from 4340, etc.

On the other hand, 4130 is very compatible with 4140 when used together in the same weldment. LANTERNMARK has designed many uprights, control arms, and other suspension/vehicle components over the years using combinations of these and other chromoly alloys. Heat treating processes and welding fillers must consider the combination of the alloys present, and the strength of the overall component will be limited to the lesser of the combined materials, but otherwise you can achieve some very good benefits and efficiencies by using combinations of these steels. The 4140 does not preclude or detract from the use of 4130 in a combined weldment, other then some potential sacrifice in weldability. However, with proper welding procedures, pre and post heat practices, and appropriate welding rod selection, most fabricators will have no problems.

Many builders do not follow through with the heat treating of parts which are constructed with chromoly. We do not recommend not heat treating chromoly fabrications in general, however since this is a common practice, it is another good reason for us to use 4140 N (“normalized”) in our fab elements. This is also referred to as condition “D”. The material in a normalized condition is much stronger than when in the annealed condition, and even after welding, most if not all of the part will retain a higher strength level than if it were annealed.

For comparison, 4130 N will have a yield strength from around 60-75 ksi depending on the form of steel you are using; cold drawn seamless tubing being closer to the 75 ksi mark, and hot rolled bars and plates coming nearer 60 ksi yield. On the other hand, the 4140 N bars and plates will be closer to 100ksi. The machinability of the 4140 N is also a little better than that of 4130 N. The harder 4140 is not as “gummy” as the 4130.