Michael Waltrip Racing demos its Jet Edge waterjet on “Modern Marvels”
May 2012 - For professional stock car team Michael Waltrip Racing, the media spotlight is a familiar glow. Based in Cornelius, N.C., and founded by its Daytona 500-winning namesake, MWR builds more than 50 cars per year that race before scores of NASCAR fans.
Perhaps less visible to the NASCAR faithful but foremost to race day performance is the team’s car fabrication. “Modern Marvels”, the documentary TV show exploring technology and its uses, recently gave a glimpse into MWR’s workshop.
The segment was shot for the episode “Under Pressure,” showcasing the science behind high-pressure applications. On the show, MWR demonstrated the power of its waterjet manufactured by Jet Edge Inc., St. Michael, Minn.
The company has used Jet Edge waterjet-cutting technology since 2008 and upgraded to the X-Stream water intensifier pump the following year. The X-Stream generates up to 90,000 psi, delivering a stream at almost 2,000 mph as it exits the nozzle. It’s integrated with a Jet Edge high rail gantry waterjet system.
For parts such as chassis, suspension and body components, MWR cuts steel (1018, 1045, 4130), aluminum (6061, 7075, 5052), polycarbonate and Tegris, a lightweight thermoplastic composite. The waterjet tackles thicknesses from 0.01 in. to 6 in. in steel and aluminum, says Nick Hughes, technical director at MWR. Depending on the material, cutting 2-D patterns and profiles into metals isn’t always easy, he says.
“The waterjet is fast, can cut complex shapes through very thick material and not leave a hardened, heat-affected edge,” Hughes says. “Also, the cut is very fine, so there is less wasted material.”
Among MWR’s notable vehicles are the #55 Aaron’s Dream Machine Toyota Camry driven by Michael Waltrip, Brian Vickers and Mark Martin, the #56 Napa Auto Parts Toyota Camry piloted by Martin Truex Jr. and the #15 5-Hour Energy Toyota Camry driven by Clint Bowyer, according to a press release.
Nancy Lauseng, marketing director at Jet Edge, says the X-Stream cuts faster than a 60,000 psi system–up to 50 percent depending on the material. For MWR, which cuts about 1,000 parts with the waterjet for each car, that’s a huge gain. “By cutting faster, MWR is able to get design improvements to the racetrack two weeks faster, which is huge in their highly competitive sport,” she says.
From shop to screen
Extensive behind-the-scenes production and a full day of filming translated into about a five-minute segment, replete with up-close waterjet cutting shots, montages of pressurized environments and metal cutting comparisons. “I was pleasantly surprised with how much footage they did use,” Lauseng says.
Before the shoot, the “Modern Marvels” crew interviewed Michael Wheeler, Jet Edge’s R&D engineer, to understand how waterjet systems work and how ultra-high-pressure water is produced. Lauseng assembled descriptive text, diagrams and supplemental video footage for the show’s producer, Half Yard Productions. When it was time for the shoot, she and Wheeler traveled to North Carolina. Wheeler appears in the segment as well, detailing waterjet’s power and capabilities.
“It was very exciting to be involved in the shoot,” she says. “The crew was a blast to work with.” Off-camera, MWR has improved its cutting speed by 35 percent, is using about 25 percent less garnet abrasive and has reduced operating costs by 30 percent.
“They upgraded to the X-Stream specifically so they could increase productivity,” says Lauseng. “They have been able to reduce waterjet operating hours from 60 to 65 hours per week to 40 to 50 hours per week, saving on labor and overhead.”
By slashing production time, MWR has been able to develop a side business building cars for other race teams. FFJ
If you like racing, check out FFJTV at Chicagoland Speedway
