Off-road racing demands suspension that can handle extreme terrain, and Dane from ‪@FOXFACTORY‬ is here to break down the tech behind their world-class dampers. From remote reservoirs to internal and external bypass systems, we explore how Fox designs for the brutal conditions of off-road racing events like the Dakar, Baja 1000 and the Finke Desert Race while keeping the tech scalable for daily drivers.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

Topics discussed in this SEMA interview also include how heat management, damper size, and semi-active Live Valve systems let vehicles like the Ford Raptor and custom trophy trucks tackle everything from high-speed whoops to precision jumps.

Also included is a quick explanation of how the system uses ECU data, including from aftermarket options, including MoTeC, rather than complicating things with their own separate electronics. This means existing sensor data is also used, including steering and throttle inputs, pitch, yaw, and of course, speed.

Blow off valves and wastegates are fairly simple in their operation, but correctly sizing and fitting them requires a lot of careful consideration if you want to get the most out of your turbocharged engine.

This week, Gregg Jones of TiAL Sport — someone who’s been in the turbocharging game since the mid-eighties — is here to get us up to speed on these simple yet crucial components.

Use TIAL50 to get $50 off HPA’s EFI Fundamentals course: https://hpcdmy.co/efifundb

Gregg started his career in performance cars in the dark ages of turbo technology. It was the mid-eighties, and there weren’t a whole lot of good options around for the aftermarket boost industry — but working with rudimentary laggy turbos and cast-iron wastegates got Gregg thinking that he could create something much better — so he did. TiAL Sport was formed in 1993 and the company quickly blossomed as turbocharged European and Japanese imports began to filter into the mainstream.

In this conversation, Gregg talks us through those early days, touching on how much room for improvement he saw and how his company was able to step up the game year after year. Gregg discusses how his products are designed, tested, and made — as well as where he sees the industry going in the future.

We then move into the tech-focused section of the episode, where Gregg drops knowledge on all things turbocharging — especially when it comes to speccing, fitting, and getting the most out of blow off valves and external wastegates. There are some real nuggets of gold to be found in this conversation, and anyone who wants to better understand boosted engine applications is going to be better off for listening to it.

Follow Gregg here:

IG: @tialsport, @xonarotor
FB: TiAL Sport
WWW: tialsport.com, xonarotor.com

Don’t forget, you can use TIAL50 to get $50 off HPA’s EFI Fundamentals course: https://hpcdmy.co/efifundb

Timestamps:
0:00 UNTAPPED Potential? BOVs and Wastegates Decoded
3:14 How did you form an interest in the automotive industry?
8:10 Move to Florida and exposure to turbocharged vehicles
10:24 Early cast iron HKS wastegate
15:34 Why did it take so long for V bands to become the standard?
17:23 What materials did you move to instead of cast iron?
19:12 How have we overcome turbine back pressure?
21:39 What was the design process for these wastegates?
29:21 What are the challenges in designing a wastegate?
34:13 What is the actual benefit to a blow off valve?
40:52 Where’s the best place to put your blowoff valve?
48:13 How do blow off valves work with MAF sensors?
52:32 Do we need to tune the blow off valve for the application?
54:30 Do you have a size guide for blow off valves?
56:17 How do we choose the right wastegate?
1:01:46 What’s the best way to mount a wastegate?
1:04:36 Wastegate springs explained
1:11:56 Is there still room to improve wastegates and blow off valves?
1:16:05 How did you start working with Robert Young and Xona Rota?
1:21:59 What’s next for turbo technology?

Engine swaps on modern vehicles are no easy task, but Stewart from ‪@mesocustoms1696‬ has taken it to the next level with this insane Toyota Tacoma build, featuring a 6.2L Hellcat supercharged HEMI under the hood. In this video, dive into the challenges of integrating late-model electronics and why a turnkey Hellcat system from Cleveland Power and Performance made this swap not only possible but seamless.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

With 800-900 horsepower on tap, at the SEMA Toyo Tires Treadpass stand Stewart explains why the Hellcat package was chosen over alternatives like the 2JZ, emphasizing the importance of retaining factory ECU integration for plug-and-play simplicity. From the OBD2 compatibility to a functional Hellcat gauge cluster and shifter, the truck now thinks it’s a Dodge—but with the soul of a Toyota.

Beyond the drivetrain, we explore the custom wide-body fibreglass panels, hand-shaped and perfected using 3D scanning and CNC routing. Stewart shares how this approach not only ensures perfect symmetry but also makes future repairs and reproduction straightforward with reusable moulds.

Whether you’re into engine swaps, custom bodywork, or the cutting-edge tech that bridges OEM and aftermarket, this Tacoma build is packed with ideas and inspiration.

Rock crawling isn’t just about getting to the top—it’s about doing it with precision, relative speed, and control. In this video, we catch up with Rodney from Lasernut Racing to break down the incredible engineering behind their single-seat unlimited class buggy, built for the toughest rock crawling challenges.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

From low weight and tight packaging to innovative techs like portal hubs and rear-steer functionality, this 10mph max speed and 42" BF Goodrich tyre-equipped buggy is a masterclass in off-road engineering. During SEMA, Rodney takes us through the key decisions, such as using a 220hp 2.0L Chevy LNF Ecotec engine for its compact size and power-to-weight ratio and the ingenious placement of the axle-mounted fuel cell for improved safety and balance.

Learn how air lockers and diff locks provide precise control, and how hydraulic winches keep the suspension loaded during vertical climbs. Plus, explore the air suspension system that allows the vehicle to adjust ride height by up to 20 inches on the fly.

On the electronics side, Rodney explains how the Ecumaster PMU16 and ADU5 Dash streamline power distribution and steering control using Blink Marine CAN-based keypads. With clever innovations like adjustable steering indicators and a ride height potentiometer, this buggy has no shortage of cutting-edge solutions.

If you’re into off-road motorsport or just love clever engineering, this deep dive into rock-crawling tech is one you won’t want to miss.

Considering striking out on your own in the performance automotive industry? There’s nothing more satisfying than building your own successful business and being your own boss but… getting it right isn’t easy.

On this episode of Tuned In, we catch up with M26 Engineering’s Matthew Bernasconi, who we first interviewed back in 2022 just as he was leaving stable employment at offroad legends Kibbetech to build his own business.

Use M26ENG50 to get $50 off HPA’s 3D Modeling & CAD for Motorsport course: https://hpcdmy.co/CADb

Matthew has designed and machined parts for the automotive and aerospace industries his entire adult life. If you’ve ever encountered any of his popular social media channels, you’ll probably already have a good understanding of just how talented he is.

This skill was what first had us reaching out to appear on the podcast two years ago, and considering that episode (linked below) ended on a cliffhanger with Matthew just about to strike out on his own, we decided it was time to fire up the mics again and get caught up on how it’s all gone.

This episode is filled with great technical chats about 3D modelling, machining, and component design, all mixed in with quality business discussions that’ll provide a whole lot of inspiration and insight if you’re ever thinking about starting your own company in the performance industry.

Listen to Matthew's first episode here: https://hpcdmy.co/mattb

Follow Matthew here:
IG: @M26Engineering, @matt_eight26
FB: M26 Engineering
WWW: m26engineering.com

Don’t forget, you can use M26ENG50 to get $50 off HPA’s 3D Modeling & CAD for Motorsport course: https://hpcdmy.co/CADb

Time Stamps:
0:00 Using your automotive skills to start your own business.
3:30 Who are you and what do you do?
4:48 What were you doing at Kibbetech?
16:22 What did you learn at Kibbetech that you then applied to your business?
18:27 How did you decide the time was right to start your business?
28:05 Did you start off just doing the design portion and outsourcing the machining?
33:30 Is making one-off CNC parts financially viable?
42:06 Did you have a business plan?
44:37 You’ve been running the business for two years, What’s that journey been like?
54:37 How did you transfer from rapid prototyping to production-style work?
1:00:35 How have you decided what makes and models to support?
1:06:58 How big are these production runs? How many parts are you making at a time?
1:11:18 Why are your parts better/different from the competition?
1:17:10 What’s your opinion on business-to-business or direct-to-consumer sales?1:20:10 How does product development work?
1:25:25 Liability on your products, Is it a concern?
1:28:09 What does M26 look like in 5 years?
1:35:38 Final three questions.

Building high-performance engines just got easier! In this video, we’re with Tom from Hughes Race Built to explore how they’re solving one of the biggest challenges in performance engine building: finding the right tools for the job. Whether you’re tackling a 2JZ, RB26, SR20, 4G63 or even Honda’s K and B series, Tom’s specialized and generic option toolkits are designed by engine builders, for engine builders, to simplify the process and make it more accessible for enthusiasts and pros alike.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

From engine-specific kits priced around $580 USD ($1,000 NZD) to their innovative hydraulic balancer puller, these tools take the frustration out of tasks like removing front pulleys, compressing valve springs, and installing piston rings. Tom walks us through how these purpose-built solutions, like their adjustable billet ring compressor, bring the precision of CNC machining to a wide range of bore sizes without the need for multiple tools.

If you’ve ever struggled with the limitations of universal tools or wished for something purpose-made for your favourite JDM engine build, this is the video for you. Check out the solutions that are filling a major gap in the market and making engine building more enjoyable than ever.

Find out more at https://hughesracebuilt.com/

Running a 725hp Texas Speed LS-based build and TREMEC Magnum transmission, Cam Cocalis has followed on from his LS3 V8 Toyota 86 build with a full chromoly tube frame BMW E30 Vert project and pushed himself to dive into some new build aspects, a C6 Corvette suspension swap in particular, as he continues to learn the ins and outs of fabrication and custom car building.

Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in

At the ‪@toyotires‬ booth during ‪@semashow‬ Cam gives us some insight into his welding progression and working process without the use of CAD, with that being a skill he wishes to learn during future projects. The CSF triple pass radiator is rear mounted to aid with weight distribution, and interestingly, this model of E30 came with rear ballast from the BMW factory. The Radium Engineering fuel system behind the Ford 8.8 rear diff also helps to get weight over the rear and a 48/52 split.

The Redux Racing ITB-equipped 7L LS-based engine is controlled by a suite of Haltech electronics, and a Live To Offend kit is fitted to the E30 care of SOS Customs handiwork. We didn't get a rundown on the full brake package, but a Wilwood pedal box is equipped which will serve Cam well if he decides to hit the track for some time attack racing in the future.

*** We’ll be taking a break over the Christmas/New Year period and will be back in action mid-January.

That means that although there won’t be any new episodes for a few weeks, we’ll be taking another look at some of our favourite conversations from 2024. ***

If you’ve spent any time on YouTube, you’re probably already aware of this episode’s guest and the various projects his channel is involved in — most famously “Project Binky”, a classic Mini running a Toyota Celica GT-Four engine and AWD driveline.

Richard Brunning from Bad Obsession Motorsport joins us to down a few cups of tea, talk motorsport, and run through the ins and outs of neverending project cars, the business of operating a popular automotive YouTube channel, and much more.

Use “BAD100” to get $100 OFF our HPA Motorsport Fabrication Package:
https://hpcdmy.co/fabpackageb

Richard, like many guests of this podcast, has his father to blame for his motorsport obsession. Some of his earliest memories involve hanging out in old sheds while his Dad restored vintage vehicles, tickling up RC cars to get the edge in racing, and days spent on the couch watching Formula 1.

This early focus on all things automotive drove Richard towards a life that revolved around motorsport, first starting out in kart racing, before moving on to Caterhams, formula cars, and even some Formula Mazda racing in the States. In this episode, Richard spends time talking us through these different forms of motorsport, and discusses how each type of vehicle could be set up, tweaked, and modified within the rules in order to gain more speed.

Eventually, Richard’s good friend and eventual partner in crime, Nik Blackhurst, enticed Richard back to the UK to help him go rallying, and it was at this point, way back in 1992, that Bad Obsession Motorsport began.

Fast forward a good few years, and Richard and Nick were fed up with the car modification TV shows like Pimp My Ride, Monster Garage, and their contemporaries that were on offer at the time — none of them actually showed why and how any of the work was done. This got the pair thinking that they might be able to do better, and with that goal in mind, the Bad Obsession Motorsport YouTube channel was founded.

It took a couple of years, but Richard and Nick’s channel began picking up steam, not in small part thanks to “Project Binky”, a Toyota Celica GT-4 powered and driven classic Mini. Richard dives deep into this build, answering our burning questions — chiefly ‘Why’? But also “What’s taking so long”?

This in-depth discussion around the challenges of fitting so much engine and driveline into such a small package is a great look into what it takes to complete a complicated project to a high standard. Lastly, we also spare some time time to touch on the joys of motorsport wiring, ultra-budget racing in the City Car Cup, and making a living out of building cars on YouTube.

Follow Bad Obsession Motorsport here:
IG: @badobsessionmsp
FB: Bad Obsession Motorsport
YT: Bad Obsession Motorsport
WWW: badobsessionmotorsport.co.uk

Don’t forget, you can use “BAD100” to get $100 OFF our HPA Motorsport Fabrication Package: https://hpcdmy.co/fabpackageb