On the fabrication side of the shop: Roll cage construction progresses on Ian G.'s DC2/K20 road race car. Ian purchased this race car out of the Pacific North West and upon delivery was quite shocked by the (lack of) quality of the roll cage. Ian sawed out the original cage and brought the car to us for a proper NASA/SCCA-legal cage that will provide a much higher level of protection and chassis stiffness.

First step is an ugly one: grind out all the remnants of the original cage. Not for the faint of heart but when complete, you have a clean sheet to work from!



Now that the remnants of the original cage are history we can begin by fabricating the mounting plates for the main hoop. We use 1/8" cold rolled steel plate in this instance. We will MIG weld the side plates to the floor first. A hole will be drilled into the floor so we can drop the main hoop down far enough to TIG weld ALL THE WAY AROUND all tubes welded to the main hoop. Once they are welded, the bottom mounting plate is slid under the main hoop and welded into place.



More about King Motorsports roll cage design, fabrication and installation:
http://www.kingmotorsports.com/c-248-roll-cages.aspx

Update 8/30/2013: NASCAR door bar fabrication. Nearing completion of Ian G.'s DC2 race car safety makeover!

One of our favorite Hondas is the DC2 Type R (DC2R). Mugen fitted new aero and performance parts to improve upon Honda's already formidable track-worthy Integra Type R. The aero kit fits the JDM front clip and features an aggressive, taller wing. Bronze 16" MF10 wheels and suspension upgrades make sure this lightweight Integra transfers power from the Mugen-equipped motor to the pavement.

Three-quarters rear view: clean, simple and functional!

This Mugen sketch illustrates the aerodynamic theories supporting the bold design of Mugen's functional aero body parts for the DC2R. We love how the Mugen front bumper cover and hood work together to pull hot air out of the engine compartment.

Theory is put to the test in an aero analysis in a full scale wind tunnel. Form follows function!

The Mugen intake and exhaust manifold for the DC2R!

See our currently available performance parts for the 1994-2001 Integra (DC2) in our online store!

Today we're taking you on a short tour of the Mugen exhaust/header fabrication shop. Located behind the main showroom in Tokyo, this ultra clean and efficient facility is where all the Mugen headers and exhausts are fabricated.

All Mugen exhausts and headers are constructed from polished T304 stainless steel, including all attachment points. T304 is considered the best steel available for corrosion resistance and all-around toughness. The flanges are cast stainless steel and use OEM gaskets and hardware for a precision fit.

Each exhaust and header is TIG welded on an extremely robust jig to ensure absolute perfect fitment.

Here a center resonator is packed with sound deadening material before being welded to the B pipe:

The finished product is racked before being packed up for shipping. This represents a typical production run of B Series headers.

You can check out the currently available Mugen exhaust components in our online store. You can also order a custom header made by King Motorsports. In the tradition of the Mugen headers, the dyno-proven King headers are hand-fabricated with T304 steel for any H, B or K Series and built for perfect fit and maximum horsepower gains.