Photo credit: www.motorsport.com
Denny Hamlin started strong during the early afternoon Cup practice at Martinsville Speedway, leading the speed charts after 30 laps. However, his day took a dramatic turn when a piece of rubber jammed his throttle open. In an attempt to reduce speed, Hamlin turned the steering wheel, causing his car to crash backwards into the wall. The damage to the right rear was so extensive that immediate speculation arose regarding the need for a backup car. Nevertheless, Chris Gabehart, the crew chief for the No. 11 team, and his crew at Joe Gibbs Racing opted for a different approach. They called in NASCAR’s Hawk-eye Optical Scanning Station (OSS) to assess the damage, allowing them to repair what was thought to be a totaled vehicle within hours.
Here’s an overview of the rapid repair process.
1:20 PM, Saturday
Joe Gibbs Racing personnel, alongside NASCAR officials, began evaluating the damaged No. 11 vehicle. Although Gabehart expressed disappointment witnessing the misfortune of such a competitive car, he quickly directed his team to start removing damaged panels. Within just 15 minutes, the trunk lid and rear bumper were detached, revealing the compromised rear bumper supports. Fortunately, these supports had crumpled as intended, effectively doing their job of safeguarding the driver and minimizing damage to the rear clip and fuel cell.
A NASCAR official watches the No. 11 crew as the OSS conducts its scans.
1:50 PM
To expedite the repair process, mechanics from 23XI Racing joined forces with their Joe Gibbs Racing counterparts to dismantle the rear of the car in preparation for the OSS. The OSS employs structured light scanning technology to gauge the car’s bodywork and suspension with astonishing precision, typically measuring tolerances down to 0.150 inches. While primarily used for scrutineering, NASCAR allows teams to utilize this technology in exceptional circumstances to verify how much a car has deviated from its original specifications. After a scan, the system generates a heat map that compares the car’s bodywork to a stored CAD image and an alignment sheet detailing measurements like camber and toe.
Denny Hamlin inspects the damage on the No. 11 while crew members continue their work.
The ability to perform such repairs is largely facilitated by the modular design of the NASCAR Next Gen car, which allows for easy assembly and disassembly of the chassis and bodywork. Unlike the previous generation, which had a single-frame structure that would often necessitate switching to a backup car following an accident, the Next Gen chassis features a safety cell integrated with detachable front and rear clips. This design enables mechanics to unbolt damaged components, conduct scans, and compare measurements without the need for cutting or welding.
2:00 PM
Crew members maneuvered the car over to the OSS, and within 15 minutes, they returned to the garage equipped with data that informed their decision to move forward with repairs. A large yellow storage box was wheeled into the garage, enabling mechanics to quickly access essential components, including a new bumper support and bodywork pieces.
The No. 11 crew retrieves components from the organized storage box to facilitate repairs.
A key factor in the team’s rapid recovery was their organized storage approach, employing a 5S methodology for efficient labeling and sorting. This system resonates well with Joe Gibbs Racing’s affiliation with Toyota, which incorporates the 5S method as part of its Kaizen philosophy for continuous improvement.
Three Hours Later…
Parts were affixed to the car, and the No. 11 team prepared for another scan through the OSS to verify the integrity of their repairs. The vehicle’s readings matched those recorded during the initial inspection, prompting the crew to make final adjustments to ensure optimal performance.
6:30 PM
After the car was appropriately set on the ground, it was rolled outside for engine testing and checks on the throttle body. With satisfactory measurements and overall appearance, the No. 11 crew stored the vehicle safely for the night.
Race Day, Sunday
Hamlin’s car underwent another evaluation with the OSS, leading the crew to make a few last modifications before pushing the vehicle to the grid for the race.
Denny Hamlin, Joe Gibbs Racing, FedEx One Rate Toyota Camry
The adaptable design of the NASCAR Next Gen car supports the seamless transfer of components to a backup vehicle when necessary. However, retaining the primary car that had been meticulously prepared is ideal. For the No. 11 team, effectively salvaging the vehicle allowed them to maintain the competitive edge they had gained during practice. Returning to a fully functional primary car also spared them a lengthy trip to their Huntersville facility, which could have included over ten hours dedicated to preparing a backup car. Instead, they completed the repairs on site in less than five hours, allowing the crew to conclude their tasks before 7 PM and be well-rested for race day.
Although Hamlin started the race in 37th position, he skillfully maneuvered up to the top 15 by lap 100 and ultimately finished strong in fifth place.
Source
www.motorsport.com