New Line Racing - Products Range 2011 by Sorridi Editore

SUMMARY

WHAT IS THE RADIATOR AND HOW DOES IT WORKS

A COOLER WORLD

RADIATORS WHEN IT’S COLD

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005

WHAT TO DO BEFORE YOU GET BACK ON THE TRACK

MAINTENANCE AND CLEANING THE RADIATOR

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HOW TO MOUNT A RADIATOR/2

HOW TO DEAL WITH THE HEAT

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HOW TO MOUNT A RADIATOR/1

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THIS IS THE RADIATOR-CONVEYOR

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ESSENTIAL ACCESSORIES

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HOW TO BUILD A RADIATOR

SPECIAL AND FUTURE MATERIALS

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WHAT IS THE RADIATOR AND HOW DOES IT WORK FIRST EPISODE OF THE NEW LINE RACING AREA DEDICATED TO HOW A RADIATOR IS MADE AND ALL ITS OPERATING PROCEDURES

ew Line is a leading kart radiator manufacturer. Each piece is handmade to ensure attention to detail and offer the best possible product to drivers. What is a radiator? What is it used for? How does it work? WHY DOES THE ENGINE NEED COOLING? The radiator is responsible for lowering the temperature of water-cooled engines. Without a radiator, the engine would overheat and break. Every combustion engine performs a particular operational cycle that produces heat. The 2-stroke engines have two phases. To “control” the excessive heat produced by an engine it is necessary to have a tool that

will keep it cool and never exceed a temperature of 60º C or lower than the 45º C: this is what the radiator does. HOW IS A RADIATOR MADE The New Line kart radiators look, at first glance, like a sort of grate. But they are “grates” but studied in every minute detail. The [FIG.2] the radiator masses arrive in un-worked shapes: they are made of tubes which create reeds crossed by aluminium coils. The masses undergo heat treatment processes to enable them to release heat faster, they are then worked so that the air encounters as much friction as possible. It is important for the air to come into contact with the radiator correctly as this helps the cooling process of the water that runs through

A WORLD CHAMPIONSHIP RADIATOR New Line Racing was set-up in Maranello (Italy) in 1998 by Marco Malverti, Massimo Benedetti and Alberto Frigieri. Three guys who worked for Ferrari and decided to start producing hand-made kart radiators. Today they have a company covering 600 square meters, which produces approximately 1,000 radiators a year (when they started they were making 50-100). Today they are at the top of the karting scene, not just in Italy. In fact, the New Line RS radiator was mounted on the kart that took the first three places in the SuperKF world championship held in Macau : Arnauld Kozlinski, the new champion, Aaro Vainio and Ben Hanley, all won thanks to New Line Racing.

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1 Hot water

Hot water

Radiator

Cold water

Cylinder Engine Cold air

Hot air

Cold water

the radiator masses. The sides, to which the radiator support hooks are applied are made of aluminium. The chambers form the upper and lower sections of the radiator under handmade. All the radiator parts are then assembled and tested to ensure there is no microporosity which would decrease efficiency levels. HOW DOES A RADIATOR WORK The radiator performs a [FIG.1] cooling process using air and water to cool the engine cylinder. Here’s how. The water which is located in a first chamber in the upper right section of the radiator, enters the radiator. It subsequently descends, running to the first cooling process: it flows through the reeds (very thick) which serve to increase the heat exchange surface. In simple words this means that, thanks to these fins, the water will run through the

Water Pump

radiators for longer, this will generate higher cooling capacity (in fact, when it is used in winter seasons, it has a sort of “curtain” which covers part of the radiator to prevent it from cooling excessively). This cold water is then deposited in a second chamber in the lower section of the radiator and flows towards the pump. It will then enter the lower part of the engine, cooling the cylinder to prevent it from overheating. The water is now hotter and flows out from the engine head returning to the first chamber in the top righthand section of the radiator ready to perform another cooling cycle.

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RADIATORS WHEN IT’S COLD SECOND EPISODE OF THE NEW-LINE RACING AREA DEDICATED TO HOW TO TREAT YOUR RADIATOR DURING THE WINTER.

n the winter, there are fewer races but that doesn’t stop the pleasure of driving your kart. But there is a risk that, with the cold air in this season, pleasure will never go out on the track. But with the cold air of the season, there is a risk that the radiator, completing its cycle, the engine cool too. How to avoid that happening? If you do not fancy running around the track until the arrival of spring, how to preserve the best radiator for the new season? How to realize that it is to be replaced? TWO METHODS TO AVOID TOO COLD In the last episode of the new-line space was seen as the radiator in the summer to fulfill his “classic” cooling process [FIG.1] of the cylinder of an engine using water and air. In winter, however, do not run if the necessary work on the radiator, there is a risk that the engine has cooled down too much. In short, the goal, even in December, is making sure that the engine temperature never falls below 50 º C (which, however, never exceeds 60 º C). For this to happen, there are two ways to proceed: The first is to use the radiator shutter [FIG.2] which is a tool that allows you to cover all or part of

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the grid where it enters the air (which by its action cools the water). With the availability of tools that provide instantaneous temperature of the cylinder, you can adjust the curtain covering most of the grid (thus letting less air), if the engine is too cold, or less, if the engine is too hot. The second method requires the use of third pipe (after the point of entry and exit of the radiator) with a thermostatic valve [FIG.3]. The valve, the change in temperature of the circulating fluid, open and close the passage to the radiator. For example, if the water is too cold the valve is closed (that’s the starting state), blocking the movement and by channeling the water itself in this third tube: it is “missing” step in the radiator. A pass in the third tube is always the same liquid until it reaches a temperature that will be as open (the opening is in degrees) the valve, thus releasing the passage to the radiator. It is often advisable to

clean the valve against the limestone (often) is formed and which can cause breakage. The valve does not need direct intervention of the pilot as with the curtain, but it requires much more maintenance.

maintenance for the radiator is reduced to a minimum: just empty the radiator so that no ice in the water (on average in circuit there are about 1.5 liters in winter it is good to enter the already hot water) and cover the grill to protect the “delicate” wings. Then, if desired, can also be stored outdoors without any problems. In the spring, with only a few measures (in the next episodes, ed), will be ready for the races.

UPCOMING EVENTS IN THE SPRING? When it comes time to put the kart in the garage because the climatic conditions make it impractical to track 1

Shutter

Thermostatic Valve

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A COOLER WORLD IN 2009 THE NEW-LINE HAS BEEN VERY SUCCESSFUL. PARTICULARLY WITH REGARD TO THE WORLD CUP TAKING PLACE IN MACAO WHERE THE RADIATORS HAVE MADE THE COMPANY A LEADING ROLE. AND 2010...

he new season is upon us. New-Line starts from the World Champion in office. Indeed, more. In the last World kart course in Macao, in fact, New Line was not only the radiator that cut through the finish line first company to Kozlinski on CRG, but also one that rose on both the available places on the podium with Aaaro Vainio, second, and Ben Hanley, third, both of the Maranello Racing Kart. In support of results, including the numbers of participants of the competition’s top karting: the World SuperKF 43 riders were in fact present. Just under half of them have used the radiators New-Line track. Sign of a great international importance of the brand. And a sign of a great New product value-Line. To put

forward in 2010. MARANELLO RACING KART The history of Maranello Kart in a season and Macao in the world is simple: Aaro Vainio in KF3 2009 was passed by the SuperKF. In its first year in the category of single brand has won the European Championship and finished at 2 ˚ place in the World; behind him that day, Ben Hanley, his teammate. They and other Maranello drivers have used the average of the radiator-New Line of Macao in the race. The reason for this feeling with these radiators Filini Armando explains, the Maranello Racing Team Manager: “The radiator-New Line are undoubtedly the most efficient. We use them for this reason. In addition we offer

NEW-LINE RACING info@new-lineracing.com

great consistency. We are pleased and we will continue this cooperation in 2010. “ BIREL MOTORSPORT The Birel is one of the leading Italian and international karting. This is demonstrated by the history, the results of recent years and international riders like Sauro Cesetti and Libor Toman that ran in 2009 for these colors. “As we often use the radiators Birel New Line and we do it because the feedback has always been positive” to speak on behalf of the Brianza is Roberto Voltan, sports director of Birel Motorsport. In Macao, each pilot Birel mounted a radiator of the Modena.

And the RK, the Birel team wanted by Robert Kubica (leading, in fact, his initials in the name of the brand), has been using all season radiators New-Line. THE NEW LINE AND 2010 To take stock of the season we think Marco Malverne, a founder of New Line Racing: “The continued progress and development of our radiators is also due to the invaluable support of major manufacturers who use our products in major international races. Confident that 2010 will be full of satisfaction. “ P.s. Before closing in 2009 is due special thanks to Elena Malverti, company sales director, for his work during the year.

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�� WHAT TO DO BEFORE YOU GET BACK ON THE TRACK ��

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�� FOURTH�� EPISODE OF THE NEW-LINE RACING AREA DEDICATED TO THE OPERATIONS TO �� BE PERFORMED ON THE RADIATOR BEFORE RETURNING TO THE TRACK. ��

�� if they get blocked in the the cycle) then lift the kart from �� radiator, will not create serious the side housing the radiator. �� problems, but if they end up in �� In doing so, the bubbles will �� the water pump this could be rise gradually upwards, hence �� dangerous as it will stop the away from the pump, making �� circulation of the water (for the �� sure that water is distributed �� health of the engine, of course) evenly, without the presence of �� [FIG.2]. In fact, the pump any air. Then put your kart on �� would run idle inside the air the stand, turn it on and allow �� THE BRACKETS BEFORE STARTING AGAIN �� Before taking to the track again, it is important to check the �� radiator bracket. Especially with regard to the rubbers on the �� sides. The cold winter temperatures may cause the rubber �� to harden and crack. The New-Line offers three types of �� brackets: model R (58 euro + VAT), the RS New (60 euro �� + VAT), and the Big Double (65 euro + VAT, in the photo). ��

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�� NEW-LINE RACING �� info@new-lineracing.com

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�� Engine �� it to tick over: there is no better �� way to clean the radiator �� (and warm up the kart after a �� long winter’s rest, Ed.) If, after �� the test, the water level is the �� same, this means that the work �� was done correctly, otherwise �� repeat the same procedure �� until the water reaches the �� brim of the cap even after it �� has run idle.�� N.B. It is forbidden to put �� another liquid, other than �� water, in the radiator because �� if there is a leak, it make the �� track very slippery, something �� that is very dangerous for �� oneself and other kart drivers �� on the track. �� THE DOES THE �� RADIATOR WORK? �� When the kart is on the trolley, �� heating up, you can check if �� the radiator is working. The �� simplest test, but also the most �� effective, is to put your hand �� on the upper reservoir [FIG. �� 3] and bottom reservoir [FIG. �� 4] to�� feel the temperature �� difference. As soon as the ��

kart is switched on, the upper reservoir will be warmer than

��

�1

�

�2

�� Fins �� Upper �� bowl ��

� � �

3 �

� �4 �

Pan�� lower �� one; after a while, the lower

�

�� the lower ��will also gradually �� warm up. If, in fact, this is the �� case, it means the water is �� circulating and you must wait �� for the action of the air to be �� triggered (when at a standstill, �� the radiator obviously does not �� start) to cool the water. Beware �� of just one thing: check that �� there are no leaks, otherwise �� the radiator needs changing. �� But the maintenance and �� cleaning of the karts are topics �� we will deal with in the next �� episodes.The time has come �� to remove the frost from your �� kart and radiator and get �� back on the track. But what �� must be done before starting �� the engine? What are the �� mistakes to be avoided which �� could endanger the proper ��

functioning of the kart?

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�� he time has come �� to remove the frost �� Radiator �� from your kart and �� radiator and get back �� on the track. But what �� must be done before starting �� the engine? What are the �� mistakes to be avoided which �� Air bubbles �� could endanger the proper �� functioning of the kart? �� Water pump �� PRECAUTIONS TO BE �� TAKEN BEFORE GETTING �� INTO YOUR KART �� The best time to work on bubble and there would be an �� the radiator, it when your incorrect pressure of the water �� kart comes out of winter flow in the circuit which, of �� hibernation. Once you have course, can trigger a high risk �� checked the situation of the of engine failure. �� fins [FIG. 1] in the grille (just to �� clarify, if the situation is critical �� HOW TO DEAL WITH �� and they are all blocked, it is AIR BUBBLES �� better to mount a one new), You must follow a specific �� you must fill the radiator with �� procedure to avoid this �� water. Do not simply put the process: top up with water �� water in and close the radiator �� to the brim of the cap (you �� cap, because this can create need to�� fill it to the top so that �� air bubbles. These air bubbles, �� water is present throughout ��

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MAINTENANCE AND CLEANING THE RADIATOR EPISODE FIVE OF THE NEW-LINE RACING AREA DEDICATED TO KEEPING YOUR RADIATOR IN GOOD CONDITION. INTERNAL AND EXTERNAL CLEANING AND ATTENTION TO DETAIL: HOW TO LOOK AFTER YOUR RADIATOR, DAY AFTER DAY.

are, attention to detail and special care. Contrary to popular belief, the radiator is a part of the kart that needs special care. Without neglecting the consequences of a change of season, down-times, or simply driving off the track into the barriers during a race. Everything is important. Here’s what to do whatever happens. Looking outside and inside the radiator.

you use a conveyor, which lets in more, but dirtier, air clean it more often): the water will be very dirty. Cleaning should be done immediately, however, if the kart has come off the track. The front wheel will tend to raise the earth, dust and mud into the radiator, so make sure it is checked well after an unlucky race. If these three procedures are not done properly, this will lead to blockage of the air flow (the dirt will form a kind of wall) with consequent malfunction of the radiator and engine failure. In addition to soap and water? You can use specific detergents for aluminium mechanical parts.

EXTERNAL CLEANING Let’s start with a certainty. There will inevitably be more dirt at the top of a radiator grille, [FIG.1]: as more air enters the top section and flows up through the radiator, taking dust and various debris with it. Not to mention that the top section is also the part most subject to wear and tear. Going back to the dirt, what is “felt” the most in the various fins is the dust that rises from the front brakes (more so in the KZ karts where the brake system is most under stress). The radiator needs washing with soap and water at least once every two months (but if

CLEANING Looking inside the radiator, there is another problem: a typical layer of dust that forms with on the aluminium. Because when a radiator is idle for a few months, the internal humidity can generate this residual dust. From time to time (and especially before putting the kart into hibernation for a while) it is recommended to add some anti-limescale, 1

Front view of a radiator

Accumulation of dust Air inlet

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Overhead view of a radiator

Aluminium cap Accumulation of white dust

A RADIATOR FOR ALL SEASONS The radiator of the New RS-Line racing down. It is the best selling product range thanks to its versatility: it is perfect for summer and winter. Costs 400 euro including VAT of the adjustable curtain. The cost of the curtain is 30 euro + VAT. COMPANY New Line Racing was born in Maranello Italy in 1998 at the hands of Marco Malverne, Massimo Benedetti and Alberto Frigieri. Today they have a company of 600 square meters, which came to produce approximately 1,000 radiators per year in karting (when parties nor do they achieve 50-100). In addition, carry radiators for cars, motorcycles and quads. some specific detergent, or a specific product for cleaning radiators. Another important tip of advice: radiators have a longer working life if distilled water is used in place of tap water. It has less impurities when heated and cooled continuously (leaving less residue). ALUMINUM CAP The continuous change in temperature also affects the cleaning of the other components. Such as the Front view of a radiator

cap. When idle there will be a white powder visible, like sand [FIG.2]. It is recommended to use specific products here too. If the cap is made of plastic, then it is more susceptible to aging. Without considering the decreased capacity to maintain the required pressure. The best solution is an aluminium cap with a breather valve [FIG.3] which is more reliable. And without doubt it has a longer working life. Radiator cap with breather

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HOW TO MOUNT A RADIATOR/1 THE SIXTH EPISODE OF THE NEW-LINE RACING AREA IS DEDICATED TO UNDERSTANDING MORE ABOUT THE TECHNIQUES AND INSTRUMENTS USED TO MOUNT A RADIATOR AND ENSURE MAXIMUM PERFORMANCE

he quality of a radiator is also noticeable in the finer details: for instance, after seeing how a radiator is made (TKart November 2009, page 96), it is important to focus on the way it is mounted on a kart. What is the right position to install it? What is the right angle? There are so many questions that one episode is not sufficient to explain everything. That’s why the other secrets on how to mount a radiator will be explained in the next episode. WHERE TO POSITION A RADIATOR The position in which a radiator is positioned on the kart frame is important for the equilibrium of temperatures of components too, such as tires and brakes. The correct position: between the disc and the tire

And changes depending on a series of other parameters. But let’s take one step at a time: in absolutely normal and balanced conditions, the radiator must be mounted in the centre, between the disc and the left rear tire [FIG. 1]. If it is positioned differently, this can be detrimental to the performance of both the tire and the brake. In fact, if it covers the two components too much, this would change their temperatures. The result? Lower performance levels and difficulty in finding the right balance. And while on the subject of balance, there is another important point: positioning the radiator a bit off-centre compared to the position indicated above, will most likely compromise the overall weight distribution. The frames are built using a geometric precision which can withstand and counteract 1

An incorrectly mounted radiator wobbles around

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radiator supports must be studied in detail: they must be adjustable in length and width and therefore adaptable to any type of kart. In fact, the support brackets, which are essential, must be tailor made. They can not simply be pieces of iron adapted for use. Because, to recap, it is important that the radiator is able to withstand the vibrations of the kart in order to work properly (and not wobble around) and is as close as possible to the kart frame to prevent the frame itself from also working incorrectly: especially when it is “tightened” incorrectly to the radiator in an attempt to prevent it from moving. IN THE NEXT EPISODE The right angle to position a radiator and complete the assembling process as efficiently as possible; in addition, some ideas for the future... TO BE CONTINUED...

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HOW TO MOUNT A RADIATOR/2 THE SEVENTH EPISODE OF THE NEW-LINE RACING AREA IS DEDICATED TO UNDERSTANDING MORE ABOUT THE TECHNIQUES AND INSTRUMENTS USED TO MOUNT A RADIATOR AND ENSURE MAXIMUM PERFORMANCE

econd part (the first part can be found in the previous episode, last month) on the processes to follow to mount a radiator. Many questions and queries resolved and satisfied, just as many will be solved in this episode. Which is the correct angle to mount it on a kart? Why can’t you mount the radiator in the front section of the kart, as you do with cars?

properly when it is in either of the two extreme positions: If it is mounted horizontally on the frame [FIG. 2], it will obviously not cool the water as the air does not blow through the grilles. Likewise, if it is mounted vertically [FIG. 3], contrary to what one would think, the radiator does not perform properly because the air flows too fast through the grilles as it does not encounter any friction of the grille fins.

THE RIGHT ANGLE ON EVERY OCCASION Let’s start by dispelling two false rumours: it is not true that the more the radiator is tilted in a vertical position (with respect to the ground) the more it cools; and it can’t be said that a radiator with a larger grill will perform better and therefore cool more than a radiator with a smaller grille. The reason for both paddock “legends” is all to do with the inclination of the radiator [FIG. 1]. The radiator will not work

THE PERFECT ANGLE There is no perfect inclination angle: it varies from kart to kart, from track to track and from season to season. In winter, for example, even with a shutter, there is a risk that the engine is too cold (and therefore risking rupture). It is best to “lie” the radiator downwards forcing it work properly, whatever the condition. In summer, on the contrary, as the temperature rises (from spring to summer ...), it is recommended to “stand the

TON-TRACK ASSISTANCE When New-line provides assistance to the top champions in international competitions, it uses a tool (a type of degree wheel), to calculate the right angle of a radiator, according to the indications that the technicians recorded on the track. In the picture: the RS radiator, 400 euro + VAT.

NEW-LINE RACING info@new-lineracing.com

grille up” so that air can have a greater impact on it. As for the tracks, if in summer when it is hot, you come across a slow track, the radiator can be raised even further; this is not applicable if the track is fast, because the aerodynamics are also to be considered (not a critical component in karting, but nevertheless not negligible). Finally, as far as the karts are concerned: in KZ the water pump is fitted externally, in KF internally: therefore the yield and starting temperature of the two water pumps will be different and, consequently, also the angle of the kart. THE IMPOSSIBLE POSITIONS When the temperature begins to rise (soon, given the season, a special episode on how to manage your radiator in Sahara style temperatures) you see all sorts on the track. Radiators mounted behind the seat or additional pieces scattered everywhere. But why is the radiator never mounted on the front of the kart, perhaps right on its nose? It’s all a question of balance. The radiator, in fact, also has (in addition to the main task of cooling the engine) an important role in “offsetting the weight” of the engine and driver. Moving it would incur rethinking the entire

design of the frame and relative weight distribution. So, to recapitulate, in the future who knows, but for the moment, also from a functionality standpoint, the radiator mounted on the front would be affected by the lack of proximity to the engine and the excessive weight for the plastics currently on the kart. Without even going into all the danger and rupture possibilities in the event of any contact on the track. 1

Angled radiator Radiator

Output air

Input air

Horizontal radiator Air cannot enter

Vertical radiator

Input air

Output air

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HOW TO DEAL WITH THE HEAT EIGHT EPISODE OF THE NEW-LINE AREA DEDICATED TO HOW TO MANAGE A RADIATOR DURING THE SUMMER SEASON

ith the arrival of summer, it becomes crucial for the kart to make the most of the radiator. But not only. There are many components to use in order to drive faster without, above all, breaking the engine. WHICH RADIATORS TO USE To start with, let’s run through what types of radiators exist. New-line has three different sizes in its range: the smallest is the r 125 which is 20 cm wide; the rs 125, which is fine all year round and 24 cm wide, while the big version [1] is 29.5 Cm wide. The latter is specifically designed to be used in the three summer months (in winter you would have to do too many slow laps to warm up the engine). But new-line also offers other types of radiators. The curved supplementary version [2], for example, is to be mounted behind the seat. It may not seem so but, in fact, there is a high level

of air movement passing under the seat of a kart which then rises from behind the driver’s shoulders. This mini-radiator allows you to also exploit this air to help keep the engine temperature down. And the faster the track (with long straights), the more this radiator is effective. Conversely, the difference compared to a kart without this radiator will be felt less on a mixed speed track. The official teams, especially in the kz category (which is usually the one that heats the engine more but is also less affected by the extra weight), also mount another type of radiator on the engine side: the hobby version [3]. A very narrow piece, which is as high as the others. It’s perfect, of course, for use when it is very hot. But it is not recommended for use by amateurs because it is easier to be touched (and break the radiator) and often these components are clamped quite approximately. So it’s right to cool the engine, but in a well-balanced manner.

BEFORE YOU TAKE TO THE TRACK The first thing to do is remove the radiator shutter. Not worth mentioning? You would be surprised. Many people think that simply pulling the shutter all the way down in summer will guarantee effective cooling. Wrong. The radiator works less and incorrectly. We have already dedicated an entire episode to mounting angles (number 7, tk5 2010). Just to recap, in the summer it is recommended to verticalise the radiator compared to its winter position (where it is tilted backwards, parallel to the ground). With new-line’s new adjustable brackets, you can

NEW-LINE RACING info@new-lineracing.com

THE BRACKETS BEFORE STARTING AGAIN Before taking to the track again, it is important to check the radiator bracket. Especially with regard to the rubbers on the sides. The cold winter temperatures may cause the rubber to harden and crack. The New-Line offers three types of brackets: model R (58 euro + VAT), the RS New (60 euro + VAT), and the Big Double (65 euro + VAT, in the photo). also lift the radiator off the ground. You must however not exceed the maximum height set by the federation (30 cm). But the higher the radiator, the more effective the cooling will be. To conclude, let’s look at the tubes. In winter, generally, everyone uses the black rubber ones. In summer, we recommend using the aluminium versions. Rubber tubes retain the heat, where aluminium dissipates it outwards. All racing cars, in fact, use aluminium components which are able to improve heat exchange. USEFUL ACCESSORIES A word about the conveyor. An accessory that allows more air to be channelled into the radiator. Acting as a kind of funnel. Then there are the fins that choke the air: on a fast track, the fins (or bulkheads) make sure that not even a minimum amount of air is lost before reaching the conveyor. On a slow track, it is best to allow as much air as possible to flow without using fins.

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THIS IS THE RADIATOR-CONVEYOR NEW EPISODE OF THE NEW-LINE AREA DEDICATED TO THE V-SHAPED RADIATOR, DESIGNED BY THE MARANELLO (ITALY) COMPANY’S STAFF, AND READY FOR SALE...

ew-Line’s objective is to continue to propose new options to its customers and to all karting enthusiasts. Now a new radiator is ready to be launched: The V-shaped radiator. THE 3 CORE ADVANTAGES The main feature of the V-Shaped radiator [3] is obviously its shape: and the name says it all. The radiator is in fact practically folded in half and, thanks to this configuration, it also acts as a conveyor. The first advantage is the way the air hits the grille compared to what happens with a traditional radiator: in fact, if before the air only entered vertically inside the kart, with this V-shaped radiator, the air “slams” into the reeds also at an angle, as the radiator grille is angled in respect to the airflow. Moreover,

and this is the second advantage, the [1] aluminium bulkhead, fitted at the top of the grille to close the air flow, creates a radiating mass pressure, which speeds up the flow of air and the consequently cools the water in the circuit. Last advantage: the air which used to escape from the side in a standard radiator, is now conveyed inwards by this V-shaped version. ANGLE AND MAINTENANCE The V-shaped radiator is sensitive to where it is mounted and we recommend fitting it at a more upright angle than a standard radiator (about 10 degrees before the perpendicular angle with the ground): given its special shape, it is more difficult for air to pass through without being subjected to the cooling action of the grille fins. A radiator as effective as this one, however, in addition to channelling more air, also channels more dirt, especially after leaving the track (even if the functions, in the race, remain intact). It is therefore necessary to blow the radiator more often: always do this from the rear towards the front to eliminate the dirt accumulated during the race. THE COUPLES GAME how much does a radiator

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COMPANY New Line Racing was born in Maranello (Italy) in 1998 at the hands of Marco Malverne, Massimo Benedetti and Alberto Frigieri. Today they have a company of 600 square meters, which came to produce approximately 1,000 radiators per year in karting (when parties nor do they achieve 50-100). In addition, carry radiators for cars, motorcycles and quads. like this weigh? About 150 grams more than the Big New-Line radiator. But if you calculate that its effectiveness is almost equal to what would be achieved by mounting two radiators on the kart (a Big version plus a Hobby version on the engine side), in the end, buying this radiator alone will lead to a weight saving of approximately 1 kg . The same principle applies to the cost aspect: it will be around 10-15% more than the Big radiator (in addition to materials, and taking into account the extra work needed to make it), but if you add up the cost of the Big radiator plus a Hobby radiator, the savings you get buying a V-shaped radiator is about 100 . If, then, you consider that you can use the [2] RS brackets that can be fitted on all New-Line radiators... CONCLUSIONS If it is 40°C on the track (and considering the temperature of the engine under load), the radiator is still able to maintain the water in the circuit at a temperature of 50°C, and that is just 10°C warmer. And the higher

the temperature, the more you feel the difference in effectiveness compared to other radiators: the water temperature can remain about 20°C lower. In short, these extreme features make it perfect for hot tracks such as those in Southern Italy and Spain. But not only.

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ESSENTIAL ACCESSORIES TENTH EPISODE OF THE NEW-LINE SPACE DEDICATED TO THE ACCESSORIES AVAILABLE FOR KART RADIATORS.

he core asset is always the same, the radiator. But there are many accessories that can help the radiator to perform better and last longer over time. RADIATOR SHUTTER This helps protect the radiator, completely or partially during the winter months or mid seasons. Is adjusted up or down depending on how much of the radiating surface is to be exploited: the hotter it is, the more open the shutter should be. CONVEYOR

An accessory that allows more air to be channelled into the radiator. Acting as a kind of funnel. Then there are the fins that choke the air: on a fast track, the fins (or bulkheads) make sure that not even a minimum amount of air is lost before reaching the conveyor. On a slow track, the fins are less effective. BRACKET KIT Without these, the radiator can not stand up. The 2010 version of these

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brackets, compared to the previous version, can now be adjusted: it is possible to â&#x20AC;&#x153;liftâ&#x20AC;? the radiator as high as permitted so that its level of efficacy is improved. HEATSINK

A dissipater is installed instead of a piece of rubber tube. Cut the black tube and insert these components that help to cool the water. CAP

The new cap is made from one-piece aluminium. Despite the vibration of the kart, it ensures there is less dispersion of steam compared to the plastic version. WATER RECOVERY RESERVOIR Required by regulation to capture any steam or liquid overflowing from the cap if the water boils or the pump breaks. It is important to secure it behind the radiator,

but in a position that does not impede the flow of radiating air: it must never block any air. ALUMINIUM TUBE During the summer months it provides for better dissipation of heat during water flows. The black rubber tube actually attracts more heat. BULBS

They have a magnetic base and jointed tips and are used to check the status of the radiator: to check, for example, for any signs of limestone. The kart preparation mechanics check the carburetion in the cylinder. They are also useful to check the condition of the springs through the clutch hole. In short, they are ideal for use on all critical points. BAFFLE

This is installed to prevent the hot air from being discharged onto the rear tire

on the radiator side. The left rear tire, in fact, even over the same travel distance on the track, heats up more and is more subject to wear and tear. An example. The larger the radiator the more it cools the engine: but if the tire is worn out excessively (without a baffle), the lap time will be the same. It conveys hot air on the side. It is a standard accessory on the Big radiators, and can be mounted separately on all the others. ANTI-VIBRATION BRACKETS These connect the brackets to the radiators. In fact, the rubber tends to dry out and crack over time. These are screws with rubber in the middle. It is recommended to fix them in line with the bracket pin. The rubber must be in good condition: if it dries out or breaks it will perforate the radiator. They should be changed once a year.

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HOW TO BUILD A RADIATOR ELEVENTH EPISODE OF THE NEW-LINE AREA DEDICATED TO HOW BUILD A RADIATOR FROM SCRATCH. STEP BY STEP.

irst of all, it is worth stating that kart radiators are all hand built. An experienced mechanic can make up to 5 a day (with ready cut parts). There are several steps involved in order to obtain the finished product. The first step of the work consists of preparing the parts, the second step involves assembling the prepared parts and the third step is dedicated to quality control. PREPARATION BEFORE ASSEMBLY Unlike the standard procedure in the past, New-Line has a special grille made and designed specifically for karts. This grille, which is delivered to the company in blocks [1] about one meter in size, has several characteristics that make it perfect for karts:

it has reeds, small spaces where the water passes through to cool, which are thicker than before. The grille is also thicker and therefore more resistant. These grille blocks are then divided (into two, three or four parts depending on the radiator being built) using a band saw. Sheets of aluminium are used to make the sides of the radiator and the reservoirs [2]. These aluminium sheets are cut using a shearing machine then conveyed to a stamping press, which gives them their final shape. The stamping press is set to create different the different shapes of the radiator components: for instance, the upper reservoir will also have the shape of the cap (which will be added later) compared to the lower reservoir which does not. The same applies to the sides.

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ASSEMBLY Once the parts have been stamped and prepared, they are connected, trimmed, filed, ground or cut by hand to ensure they are perfectly aligned with the grille. The reservoir [3] is then checked to make sure it rests perfectly along the entire length of the grille. The same process is done on the sides. Then mechanics work on the pieces to be filed if there are any imperfections. Finally, everything is assembled together with some spot [4] welding to fix the radiator in place (an additional weld seal is applied as, when it heats up, the metal sometimes twists out of shape [5]). Finally, the last components are added: the cap, for example. First of all a lathe is used to create the thread which will be used to screw on the cap then, using a special matrix, it is placed on top and everything is welded together. QUALITY CONTROL The next step is to immerse the radiator in a kind of tub to see if there are any small holes: in short, that the welded seams are free of porosity. This process is called â&#x20AC;&#x153;putting the radiator under pressureâ&#x20AC;?. The water pressure in the tank is about one bar. Under the tub, there is a light which highlights any porosity. All New-Line radiators undergo strict quality control processes. It is dried several times under a stream of hot air, otherwise

the water will create stains or oxides which will ruin the aluminium. To conclude, the radiator is brushed [6] to remove impurities from welded seams and stains from the aluminium. Finally, the radiator is packaged and sent to the warehouse ready for delivery.

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SPECIAL AND FUTURE MATERIALS ELEVENTH EPISODE OF THE NEW-LINE AREA DEDICATED TO THE SPECIAL MATERIALS USED TO MAKE A RADIATOR AND A LOOK AT WHAT THE FUTURE HOLDS...

ould a radiator be made from another material? It is made from a particular material? And the accessories? There are many questions about the materials used and usable when making radiators. And then an innovation for the future. That is already geared up to go... RADIATOR MATERIALS Currently radiators are made of aluminium [1]. It is the best material for go-karts. Copper has a cooling capacity which is equal to, or even higher than, those of aluminium, but also has a crucial flaw when it comes to racing: weight. A copper radiator would be too heavy when racing in competitions: the kart would suffer losing important tenths of seconds. You need to achieve the right balance between performance and weight. This is why aluminium is the best material. New-Line, in this respect, relies on companies specialising in the treatment of these materials. These companies take the aluminium and increase its mechanical properties. For example,

New-Line aluminium radiators reach a higher heat exchange performance (then there are companies who soften or harden the aluminium, such as companies that produce frames). ACCESSORY MATERIALS The radiator shutter is a very important accessory in colder seasons, as we have already discussed. But it may happen that in Autumn and Spring, the shutter will be fitted on the radiator when the sun is very hot. The rubber belt that holds the shutter is generally very sensitive to sunlight, heat, petrol and sprays: it tends to dry out and break or crack. The belt used on the NewLine shutters [2] is made of a special material that is usually used for hospital equipment. A belt that is virtually eternal which is hand welded to the radiator. THE RADIATOR OF THE FUTURE Here’s the future. The fan [3] produced by New-Line is awaiting FIA approval (no regulation provisions forbid its use), but it has all it takes to become a revolution for radiators. It is a really simple accessory. What problem does it solve? In karting, when you’re on the straight and

COMPANY New Line Racing was born in Maranello Italy in 1998 at the hands of Marco Malverne, Massimo Benedetti and Alberto Frigieri. Today they have a company of 600 square meters, which came to produce approximately 1,000 radiators per year in karting (when parties nor do they achieve 50-100). In addition, carry radiators for cars, motorcycles and quads. driving fast, the engine has no real temperature problems. The temperature rises when you get to a mixed section of the track, because the speed decreases and there is less heat exchange. The NewLine fan, when you’re on the straight, picks up speed (it “launches itself”) and the speed it maintains, even when the kart is tackling a mixed section, is faster than the flow of air that arrives. It acts like a hand-wheel. Then it slowly slows down until it launches itself again on the straight. In short, for most of the mixed

section it sucks in much more air than it would receive under normal conditions, with significant benefits for the cooling of the engine. It allows the radiator to perform as if it were constantly on the straight. In addition, it also acts as a baffler because it exhausts the hot air from the back of the radiator, well away from the tire and brake that could otherwise wear out or overheat. It suctions and baffles the air. The fan can not be bought yet, but the future of radiators has already begun.

3 2

Belt radiator shutter

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