GP3 2013

USER MANUAL
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Release 1.4
12.06.2013
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Pag. 2 di 63
 Summary

MAIN VIEWS ....................................................................................................................................... 4

DIMENSIONS ...................................................................................................................................... 6
GENERAL AGREEMENT AND WARRANTY ............................................................................... 10
MILEAGE OF CRITICAL COMPONENTS .................................................................................... 11
CRACK CHECKS ............................................................................................................................... 12
SAFETY WHEEL TETHERS ............................................................................................................ 13
SUGGESTED SETUP ........................................................................................................................ 15
SETUP ADJUSTMENT ..................................................................................................................... 16
RIDE HEIGHT SETTING ................................................................................................................. 20
VERTICAL PRELOAD ADJUSTMENT .......................................................................................... 21
DAMPERS OPTIONS ........................................................................................................................ 22
FRONT SUSPENSION PICK-UP POINTS ...................................................................................... 24
FRONT STIFFNESS ......................................................................................................................... 25
REAR SUSPENSION PICK-UP POINTS CFG A2-B2-C2-D2 std ................................................. 26
REAR GEOMETRY ADJUSTMENTS .............................................................................................. 27
REAR STIFFNESS ............................................................................................................................ 28
STEERING ASSEMBLY.................................................................................................................... 29
ROCKER MAINENTANCE ............................................................................................................... 30
HUB ASSEMBLY ............................................................................................................................... 33
PEDALS .............................................................................................................................................. 35
THROTTLE PEDAL HYDRAULIC DAMPER ................................................................................ 37
FIRE EXTINGUISHER ..................................................................................................................... 40
BALLAST ............................................................................................................................................ 42
GEARBOX HYDRAULIC HOSES LAYOUT ................................................................................... 44
FRONT UPPER WISHBONE MOUNTING WARNING ................................................................ 45
EXHAUST INSTALLATION ............................................................................................................. 46
APPENDIX-A BRAKE SYSTEM ..................................................................................................... 47
HIGH ROLL BACK” CALIPER PISTONS SEALS ......................................................................... 48
2013 AERO MANUAL........................................................................................................................ 49
TECHNICAL BULLETINS ............................................................................................................... 63

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MAIN VIEWS

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Pag. 5 di 63
DIMENSIONS

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Pag. 7 di 63
Tub Reference Plane (on red) Gbox Reference Plane (on red)

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Front Track mm 1585

Rear Track mm 1520

Wheelbase mm 2880

Overall Length mm 4620 From nose tip to rear edge of rear crash structure

Overall Width mm 1872

Overall Height mm 1043 From tub bottom face to camera upper surface

Weight 569 Kg (without driver)

Front suspension Push-rod, twin dampers
Rear suspension Push-rod, twin dampers
Chassis Carbon sandwich with AL honeycomb
Bodywork Carbon / Fiberglass prepreg with NOMEX
honeycomb
Composites DALLARA with DELTA TECH materials
Gearbox Gears and differential Hewland GP3 MLI Gearbox. Six ratios plus reverse
gear
Springs Front spring Dallara Eibach 36mm ID - 2” ID REAR
Dampers KONI 2612-969-744 Front (2 ways adjustable,
bump and rebound)
KONI 2812-970-745 Rear (2 ways adjustable,
bump and rebound)
Fuel cell PREMIER – FT3
Extinguisher system LIFELINE
Steering wheel XAP design
Steering release system Sadev design
Coolers/Exchanger Dallara
Rims O.Z. 13” x 10” front – 13” x 12.5” rear
Brake system BREMBO Calipers – AP Master Cylinders – Brembo
disc & pads
Battery DEKA ETX20L
Seat belt SABELT
Engine Type Advanced Engine Research V6 3000cc.

Pag. 9 di 63
 GENERAL AGREEMENT AND WARRANTY

Motor racing is not covered by warranty due to the intentional choice of drivers
to race in a dangerous environment

DALLARA indicates that, under normal operating conditions, this model of car, when new,
would not show failure in structural components (apart from components listed below)
before it has completed around 10000 Km . This holds true if necessary maintenance and
checks are provided and if the car had no previous accidents.
DALLARA is not responsible for incorrect chassis repairs, if made outside its factory or in
centres not authorized by DALLARA.
Chassis should be checked for structural failure not later than two years after delivery
from DALLARA factory, and after each major accident. After first check or after any
major accident it is mandatory to check the chassis every year in a centre authorized by
DALLARA.

Pag. 10 di 63
 MILEAGE OF CRITICAL COMPONENTS

The following parts must follow a life-mileage program for periodic maintenance /
replacement / refurbishment / dimensional and crack checks.
Listed below are typical expected life ( in kilometres ) to be intended just as a starting
reference.
For safety reasons, please contact immediately Dallara if you discover premature wear or
problems

SUSPENSION
Suspension w/bones and pushrods 5000 km
Anti Roll Bars and anti roll bar adjustable blades 5000 km
Suspension ball joints 4000 km
Front and rear rocker axial and radial needle bearings 4000 km
Rocker caps 8000 km
Front hubs 8000 km
Rear hubs 8000 km
Rocker ball joints 2500 km
Front suspension studs 8000 km
Front upright 8000 km
Rear upright 8000 km
STEERING
Steering column and tie rods 5000 km
Steering rack and pinion 8000 km
TUB and BODYWORK
Brake pedal 5000 km
Chassis to Engine installation studs 10000 km
Underwing stays 3000 km
WHEELS AND TRANSMISSION
Brake disc bell (unless fretting occurs) 3000 km
Wheel rims 5000 km
Wheel bearings 5000 km
SYSTEMS
Wiring Loom 10000 km
Water Radiator & Intercooler (unless fins getting damaged) 10000 km
WING ASSEMBLIES
Front and Rear wing assemblies (including support plates between nose box and front 10000 km
wing, and between lower rear mainplane and rear crashbox).
Front wing pillars 3000 km

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 CRACK CHECKS

Routinely perform crack checks on structural parts and after every accident. Among them:
Rims
Seat harness brackets
Brake disc bells
Wishbones, Toe links, Track rods and Pushrods
Uprights (visual after every event, with die liquids every 2 events or after shunts).
Suspension brackets, steering arms and rockers
Anti roll bars and anti roll bar adjustable blades.
Wing Assemblies

Pag. 12 di 63
 SAFETY WHEEL TETHERS

Dallara recommend replacing wheel tethers if one or more of the following conditions are
met:
1. The cable has been on the car for 12 months
2. The car has been in an accident.
3. The cable has been damaged, i.e. the braid, tape or mould have been damaged
exposing the fibre, the cable
or cover has been cut, the cable has been over-tensioned (cables are not designed to be
exposed to any load prior to an accident)

Pag. 13 di 63
At the rear the tether cables can be routed as in following picture , that is along the leading
edge of the rear leg of the top suspension wishbone. Ty-raps or tape can be used to fix the
tether to the suspension arm.

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 SUGGESTED SETUP

Ride Height Axle 21 mm

Rate 1200 lb/inch
Springs
Preload 1/2 Turn 1/2 Turn
Bump Rebound
Setting 3 3
Bump stop type Smac Blue
Damper B.S. length - mm
Front Packers - mm
Free work space 7 mm
with car @ ground
Bar Ø30 x 5 Blade 170mm
A.R.B.
Setting Rocker Outer (Stiff) @ P1
Camber -3° -3°
Toe 1mm OUT 1mm OUT
Caster Std. Std.

Ride Height Axle 38 mm

Rate 800 lb/inch
Springs
Preload 1/2 Turn 1/2 Turn
Bump Rebound
Setting 3 3
Bump stop type Smac Blue
Damper B.S. length - mm
Rear Packers - mm
Free work space 16 mm
with car @ ground
Bar Φ16mm Solid - Ti Blade
A.R.B.
Setting Rocker Inner (Soft) @ P3
Camber -1° -1°
Toe 0,5mm IN 0,5mm IN
Caster - -

Ramps brake 45°

Ramps power 60°
Differential
Working faces 6
Preload 40 Lb/ft

Front Flap C4 - 23°

Front
Gurney 10mm
Aero
Rear Biplane A4 - 20°
Rear
Gurney 10mm

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 SETUP ADJUSTMENT

Positive change in: Means:

Ride Height car moves up
Toe toe-out
Camber upper part of rim outward
Castor lower part of rim points ahead

FRONT
HEIGHT References Front
Monocoque reference on Distance from ref. to
FWA 564 car bottom
Pushrod lenght / Ride
height change 1mm => 1,834mm
1 adj. turn => 2,328mm(pushrod length) =>
Adjuster effect 4,27mm(ride height change)
Motion Ratio 1,115 Wheel/Spring
0,897 Spring/Wheel

Toe References Front

Toe link lenght/ Toe
change 1mm => 0,662°
Adjuster effect 1turn => 1,058mm

Caster References Front

FLWB aft leg lenght /
Caster change 1mm => 0,47°
Adjuster effect 1/2 adj. Turn => 0,249°

Camber References Front

Spacer 1mm => 0,3°

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 REAR

HEIGHT References Rear

Gearbox reference on Distance from ref. to
RWA 362,76 car bottom
Pushrod lenght / Ride
height change 1mm => 2,779mm
1 turn => 2,328mm(pushrod lenght) =>
Adjuster effect 6,46mm(ride height change)
Motion Ratio 1,283 Wheel/Spring
0,779 Spring/Wheel

Camber References Rear

Spacer 1mm => 0,335°

Track rod References Rear

Spacer 1mm => 0,39°

Spacers to adjust camber are available in the following thickness.

FRONT: 1.0, 1.5 and 2.0 mm
REAR: 0.2, 0.4, 0.5, 0.6, 0.8, 1.0, 1.2, 1.5 and 2.0mm.

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 RIDE HEIGHT SETTING

 Ride height is fundamental to setting and changing the aero balance of the car.
 A lower car improves performance thanks to its lower centre of gravity.
 The easiest way to measure the ride heights is checking the FR and RR distances
between the skid block wood and the set-up floor, with the driver on board and tyres at
hot tyre pressure. This is the only method which takes into account the ride height
changes caused by wear on the skid block wood.

It might sometimes be difficult to measure ride heights directly, so we also provide

alternative references.

“D" = Distance from RH measuring platforms to the ground

At the front end of the car you have:

three platforms at 559mm from the car’s reference plane, on top of the tub at the wheel
axle. Considering that the skid block ground facing surface is 5mm lower than the
Reference Plane; you can calculate the effective front ride height by:

Front Effective Ride Height = “D”-559-5

FRH measuring platform

At the rear end of the car you have:

Two platforms on top of the gbox case, at 343,25 mm from the car’s reference plane;
aligned with the wheel axle.
Considering that the skid block ground facing surface is 5mm lower than the Reference
Plane; you can calculate the effective rear ride height by:

Rear Effective Ride Height = “D”-343.25-5

RRH measuring platform

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 VERTICAL PRELOAD ADJUSTMENT

Remind there is always some ‘pre-load’ in the damper: typically this is 24-27kg for the
standard Koni damper. This ‘pre-load’ depends on damper make/type and comes mainly
from the internal gas pressure.

In a non pre-load condition, as long as the damper is not fully extended, turning on the
spring platform changes the car ride height (and lowers the gas pressure inside the
damper). When the damper gets fully extended, turning on the platform increases vertical
spring pre-load on the car. We advise though, not to proceed this way, because some
dampers [including Koni] should not be used fully extended. Therefore we advise to use
the droop-stop for limiting rebound travel or applying spring pre-load.

Pre-load in this text is considered to be the necessary force that has to be applied to the
spring to change its length with respect to the static length value.

P = Ks x t x 2

P = pre-load in kg
Ks = spring stiffness in kg/m [(Ks in Lb/in) / 56 = Ks in kg/mm]
T = number of spring platform turns
2 = mm / turn (for standard Dallara Koni damper top)
Setting Preload

Mount the damper-spring combination with the spring platform just in contact with the
spring
Put the car including the driver on the set-up floor
Clear the droop-stop from touching the rocker
Adjust ride height with the pushrod adjusters to the desired setting [further correct for
corner weights at this point]
Bring the droop-stop in contact with the rocker
Now turn the spring platform to achieve the desired pre-load

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 DAMPERS OPTIONS

The standard options for dampers cartridges are the following:

744 Front 745 Rear

mm/s N N N N N N N N
0 0 0 0 0 0 0 0 0
10 61 -59 261 -296 66 -58 261 -281
12 76 -70 379 -379 84 -71 300 -371
15 97 -91 439 -438 100 -96 338 -432
17 119 -111 474 -476 123 -110 368 -472
23 161 -157 540 -543 169 -158 416 -503
27 215 -220 600 -601 212 -226 476 -608
40 354 -343 723 -741 271 -347 579 -743
50 413 -415 819 -835 322 -421 669 -831
70 512 -504 1015 -1026 402 -527 828 -1016
90 598 -587 1194 -1188 471 -604 990 -1185
100 637 -626 1269 -1219 508 -652 1071 -1279
150 848 -820 1617 -1343 675 -841 1445 -1591
200 1069 -1036 1758 -1440 864 -1055 1834 -1696
300 1562 -1340 1944 -1410 1300 -1519 2160 -1845
400 1799 -1460 2128 -1439 1806 -1727 2327 -1966

2500

Rebound
2000

1500

1000 744
744
500 744
744
0 745
0 100 200 300 400 500 745
745
-500
745

-1000

-1500
Bump
-2000

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The soft options available are the following:

938 rebound 967 bump

mm/s N N N N
0 0 0 0 0
10 31 102 -23 -83
12 32 141 -30 -111
15 44 178 -36 -151
17 48 229 -43 -172
23 57 296 -50 -201
27 72 366 -64 -254
40 129 507 -107 -371
50 169 596 -141 -441
70 246 781 -206 -568
90 311 965 -260 -692
100 355 1047 -290 -751
150 531 1513 -419 -1083
200 734 1863 -558 -1444
300 1150 2050 -915 -1582
400 1658 2217 -1390 -1693

2500
Rebound
2000

1500

1000

500
938
938
0
0 50 100 150 200 250 300 350 400 450 967
967
-500

-1000
Bump
-1500

-2000

Any combination of the cartridge listed above is allowed, both for front and rear
suspension.

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 FRONT SUSPENSION PICK-UP POINTS

Coordinate Z of point P9 is -21.5 mm from car bottom.

X Y Z POSITION
P1 123,000 -15,000 181,000 Bottom Wishbone Front Joint
P2 -403,000 -15,000 181,000 Bottom Wishbone Rear Joint
P3 128,836 -145,260 387,027 Top Wishbone Front Joint
P4 -305,000 -175,120 368,000 Top Wishbone Rear Joint
P5 163,000 -190,450 386,500 Toe Link Joint - Steering Box Side
P6 -35,000 -670,000 348,993 Top Wishbone Joint - Wheel Side
P7 -3,500 -719,000 155,993 Bottom Wishbone Joint - Wheel Side
P8 48,000 -706,000 348,993 Toe Link Joint - Wheel Side
P9 0,000 -803,850 -26,500 Ground Contact Point
P10 0,000 -787,350 252,993 Centre Wheel Point
P11 -18,456 -671,960 190,012 Push Rod Joint - Wheel Side
P12 -186,200 -144,412 561,651 Push Rod Joint - Tub Side
P13 -225,300 -151,180 557,340 Rocker Rotational Axis First Point
P14 -222,238 -94,941 593,116 Damper Joint - Rocker Side
P15 -523,438 -148,074 566,076 Damper Joint - Tub Side
P16 -225,300 -124,320 515,170 Rocker Rotational Axis Second Point
P17 157,000 0,000 453,500 ARB Rotational Axis First Point
P18 0,000 0,000 0,000 Center Spring Pickup on Rocker
P19 157,000 -81,850 453,500 ARB Rotational Axis Second Point
P20 174,974 -72,505 572,804 ARB Link rod Joint - ARB Side
P21 -197,674 -109,474 583,874 ARB Link rod Joint - Rocker Side
P21_OPT -193,701 -95,642 592,674 ARB Link rod Joint OPT - Rocker Side

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 FRONT STIFFNESS

Front spring Stiffness Range [Ib/In] 1000-1100-1200-1300

Stiffness@Ground Full Soft Blade Position Full Stiff MR

ARB Configuration
1 2 3 4 5
[Kg/mm] 61,79 80,00 112,23 134,22 141,41
170mm Blade/ Rocker outer point 1,152
[Kgm/deg] 1354,47 1753,73 2460,22 2942,30 3099,89
[Kg/mm] 32,96 42,68 59,87 71,60 75,43
170mm Blade/ Rocker inner point 1,57
[Kgm/deg] 722,55 935,53 1312,42 1569,58 1653,65
[Kg/mm] 25,58 36,26 55,65 69,25 73,77
220mm Blade/ Rocker outer point 1,121
[Kgm/deg] 560,84 794,89 1219,91 1518,19 1617,20
[Kg/mm] 14,01 19,86 30,48 37,94 40,41
220mm Blade/ Rocker inner point 1,52
[Kgm/deg] 307,22 435,44 668,26 831,65 885,89

MR = wheel movement /drop link x-translation (point 20)

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 REAR SUSPENSION PICK-UP POINTS CFG A2-B2-C2-D2 std

Coordinate Z of point 9 is -44.96 mm from car bottom

Pag. 26 di 63
 REAR GEOMETRY ADJUSTMENTS

DO NOT USE COMBINATIONS NOT LISTED BELOW

CFG RC A-Lift A-Squat

A1-B1 C1-D1 79,8 33,2 23,9
A1-B1 C1-D2 62 -0,6 4,9
A1-B1 C2-D1 51,5 66,9 42,9
A1-B1 C2-D2 33,1 33,2 23,8
A1-B1 C2-D3 14,2 -0,6 4,9
A1-B1 C3-D2 3,4 66,9 42,7
A1-B1 C3-D3 -15,9 33,2 23,8
A2-B2 C1-D1 99,7 33,1 23,7
A2-B2 C1-D2 82,8 -0,6 5
A2-B2 C2-D1 72 66,8 42,5
A2-B2 C2-D2 std 54,5 33,1 23,7
A2-B2 C2-D3 36,6 -0,6 5
A2-B2 C3-D2 25,5 66,8 42,4
A2-B2 C3-D3 7,2 33,1 23,7

Z coordinate (mm) Variation from std (mm)

P4(A1) 300.830 20
P4(A2) 280.830 -
P3(B1) 304.061 20
P3(B2) 284.061 -
P2(C1) 124.450 20
P2(C2) 104.450 -
P2(C3) 84.450 -20
P1(D1) 145.508 20
P1(D2) 125.508 -
P1(D3) 105.508 -20

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 REAR STIFFNESS

Stiffness@Ground Full Soft Blade Position Full Stiff

Configuration Motio Ratio
1 2 3 4 5
[Kg/mm] 49,26 62,58 84,98 99,46 104,06
30x5 ARB Body/ Rocker outer point 1,234
[Kgm/deg] 993,04 1261,71 1713,31 2005,20 2097,94
[Kg/mm] 34,21 43,46 59,02 69,07 72,27
30x5 ARB Body/ Rocker inner point 1,468
[Kgm/deg] 689,61 876,19 1189,80 1392,50 1456,90
[Kg/mm] 33,92 39,76 47,75 52,00 53,23
20x2 ARB Body/ Rocker outer point 1,234
[Kgm/deg] 683,94 801,49 962,67 1048,43 1073,23
[Kg/mm] 23,56 27,61 33,16 36,11 36,97
20x2 ARB Body/ Rocker inner point 1,468
[Kgm/deg] 474,96 556,59 668,52 728,07 745,30
[Kg/mm] 12,60 14,33 16,05 17,78 19,50
16 Solid ARB Body/ Rocker outer point 1,259
[Kgm/deg] 254,02 288,80 323,58 358,35 393,13
[Kg/mm] 9,00 10,23 11,45 12,68 13,90
16 Solid ARB Body/ Rocker inner point 1,459
[Kgm/deg] 181,45 206,14 230,84 255,54 280,23

Note:

 The Ø16 Solid RARB is a new part which features a TITANIUM blade. THIS BAR
MUST ONLY BE USED WITH THE TITANIUM BLADE

 THE TITANIUM BLADE CANNOT BE USED WITH THE OTHER BARS

Pag. 28 di 63
 STEERING ASSEMBLY

New holes must not be drilled between existing ones. This means that no more than four
(4) holes are allowed on a steering column (as in the picture above).

If an intermediate length is required, an undrilled optional steering column has to be

purchased (G31029029).

The use of a tool (available in Dallara) is mandatory to drill new holes.

Pag. 29 di 63
 ROCKER MAINTENANCE
Wear might occur on the rocker (hole) and on the rocker pin (shaft). Periodically replace
bearings to remove play.

Axial tolerance

During regular maintenance you might find the rocker is axially too tight or too loose.
Look at the following procedure: remove all pieces except for the rocker pin.

 Install first lower case hardened spacer (Front only)

 Install the lower radial needle bearing
 Install the lower “case hardened”spacer
 Add grease
 Install the rocker
 Install the upper “case hardened” spacer
 Install the upper radial needle bearing
 Install upper case hardened spacer (Front only)
 Install the cap
 Tighten with the top nut/screw.
 Measure how much force is needed to rotate the rocker from the damper pick-up
point.

If the force is more than 0.05 kg ( 0.1 lbs ), machine down the upper “case hardened”
spacer.

If the spacer is too thin, the rocker assembly has too much play, if the spacer is too
thick the rocker assembly is locked.

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Front rocker

Pag. 31 di 63
Rear Rocker

The rear rocker spins around a steel pivot (A) fitted into the gearbox case by the stud B,
fixed with LOCTITE 242. The following procedure shows how to extract the rocker and
the pivot. Contact DALLARA customer’s service regarding the special tools E and F.
 Unscrew nut C and take off the cap and rocker. (Tightening torque for nut C is 3.5 Kgm)
 Unscrew nut D with 14mm tube spanner. (Tightening torque for nut D is 5.5 Kgm)
 Fit extractor F around pivot’s outer flange. By winding on bolt E the pivot will come out.
 Remove stud B with the proper tool. The stud is fitted with Loctite in its insert. When
removing the stud, heat the stud to about 140°C to break the Loctite.

Pag. 32 di 63
 HUB ASSEMBLY
The following procedure explains how to change front wheel bearings.

Bearing Removal

a) Remove the wheel speed indicator disc by removing the M4 screws.

b) Remove the bearing nut (all nuts are Right Randed).
c) Put the upright under a press, resting it against the plane sides of it.
d) Warm the upright up to 80°C
e) Press off the hub from the upright using an aluminium jig the bearing will remain on the
upright.
f) Remove the circlip and remove the bearing from upright under a press.

 A jig to support the hub for servicing is available in Dallara

Upright assembly

a) Put the upright on a press, and using an aluminium jig press the bearing in.
b) Fit the circlip
d) Put the hub into jig and press the upright in.
e) Tighten the external platform to 80Kgm .

Pag. 33 di 63
Pag. 34 di 63
 PEDALS

The most foward position is shown in the picture.

Three different lenghts brake pedal and throttle damper push rods extensions are available
to tune the pedals position.

The use of more than one extension on a single pedal is strictly forbidden.

Pag. 35 di 63
Throttle pedal sensor assembly

Throttle pedal damper assembly

Distance “C” has to be set to:

“C” measure Throttle Damper Stroke mm
0 11.5 Min value
38.5 50 Max value

So to have an “X”mm stroke “C” has to be set to X-11.5 value.

Pag. 36 di 63
 THROTTLE PEDAL HYDRAULIC DAMPER
Four different springs will be available:

Maximun
Color Stiffness Spring Code
Stroke
3,5 pound/inch
Black 50 mm GPCOM11D024
(formerly indicated as 2.5 by mistake)
4,5 pound/inch
White 50 mm GPCOM11D023
(formerly indicated as 3.5 by mistake)

Red 10 pound/inch 50 mm GP31011D010

Green 11 pound/inch 50 mm GP31011D011

Fully extended (top figure) and fully compressed position (bottom figure)

Pag. 37 di 63
 The rebound or “Throttle-Off” setting can be adjusted by
adding or deleting the calibrated shims, and by changing the
oil density.
The bump or “Throttle –On” damping stiffness can be adjusted by modifying the hole on
the valve, which is 0,8mm; and by changing the oil density.

Pag. 38 di 63
 THROTTLE PEDAL HYDRAULIC DAMPER (OPTIONAL) – OIL FILLING INSTRUCTIONS

1 – Fit the spring and its top washer into the throttle 2 - Fill the body with hydraulic oil (5W suggested), up
body. The lower body cap must be fitted on it. to the top of the spring washer.

3 – Prepare the shaft assy with the main valve, the 4 – Introduce the shaft into the body, and push it
“throttle-off” shims stack setting, and the top cap; as down slowly to avoid oil splashing.
shown below.

5 – Bleed it as a normal damper, by moving the shaft 6 – Once the damper is bled, keep the shaft in the
up and down in order to get rid of all air bubbles. bleeding position (see page before), and secure it in
the vice on this position. After that it is possible to fix
the top cap with the circlip ring.

Pag. 39 di 63
 FIRE EXTINGUISHER

The Fire extinguisher is located behind the extractable seat.

A pressure gauge indicates the extinguisher bottle status, it is visible removing the
extractable seat.

Pag. 40 di 63
 C

B
A N

The system is equipped with:

A) Mechanically operated fire bottle

B) Internal extinguisher control
C) External extinguisher and main switch control
D) Two engine Nozzles
E) One cockpit Nozzle

Pag. 41 di 63
 BALLAST

Ballast can be located beside the ADR unit. It can be seen in picture.

All eight countersunk socket head screws must be used to retain ballast.

Up to 30.5Kg Lead ballast can be stored as shown.

Pag. 42 di 63
Type “A” ballast block plan:

rr

and Type “B” ballast block plan:

Pag. 43 di 63
 GEARBOX HYDRAULIC HOSES LAYOUT
(The images below show the GP3 2010 layout. With GP3 2013 the
hydraulic pump has been moved to the LHS of the maincase. The
table below lists the part numbers for the 2013 hoses.)

Pag. 44 di 63
 FRONT UPPER WISHBONE MOUNTING WARNING

Warning: in case of interference between FUWB fore leg’s fixing screw and the steering
box, put one or two washers under the screw head.

Possible interference

Pag. 45 di 63
 EXHAUST INSTALLATION

 In order to prevent failure of the exhaust clamp , we recommend not to tighten too
much the clamps shown below

 Due to the manufacturing and installation tolerances, the direction of the hot gas
coming out of the exhaust can vary significantly: for example the exhaust could blow
the gas of combustion directly towards the rear beamwing or, in the opposite
scenario, towards the upper mainplane. The structural integrity of composite parts
like the beamwing and the upper mainplane can be severely compromised by
exposure to such hot gas: it is therefore absolutely important:
1. To protect these elements with adhesive tape
2. To check, especially at the first runs of the car, the temperatures that these
elements are reaching during their normal functioning (max temp < 80°)

Pag. 46 di 63
APPENDIX-A BRAKE SYSTEM

Pag. 47 di 63
 “HIGH ROLL BACK” CALIPER PISTONS SEALS

As an option teams can use “high roll back” caliper pistons seals (items 10 and 11 on the
GP3 spare parts catalogue).

These seals will allow for a higher pad roll back , hence reducing the friction between the
pads and the discs when the brakes are not used.
As a consequence the pedal stroke will become slightly longer.

The following table summarizes the caliper seals options :

STD seals (8x) "High roll back" seals (8x)

Series Description
GP3 code Dallara code price GP3 code Dallara code price
Seal for d. 34.0 piston GP31310C003 COMP26591 72,40 GP31310C010 COMP26586 72,40
GP3
Seal for d. 30.0 piston GP31310C004 COMP26590 72,40 GPCOM101014 COMP265821 72,40

Pag. 48 di 63
 2013 AERO MANUAL
Release 1.3

DEFINITIONS

Aero values are given @ the following ambient conditions;

Temperature = 25°C
Pressure = 1013 mb
Humidity = 0% (dry air)

Aeroloads are function of air temperature, pressure and humidity inasmuch they affect air density.

Typically,

Higher Air Temperature by 10° F (5.5 °C) reduces downforce and drag by 3.0%
Higher Air Pressure by 1” Hg increases downforce and drag by 3.0%
Higher Air Relative Humidity by 50% increases downforce and drag by 0.5%
Drag number includes front and rear wheels contribution
Front Downforce is meant at the front axle, it includes frontal area contribution
Rear Downforce is meant at the rear axle, it includes frontal area contribution
Efficiency is Total Downforce / Drag
Balance is the Downforce split percentage on front (=100*Lf /Lt).

To calculate aero loads, D/force or Drag, multiply the given coefficients by Speed squared [m/s]
and by current air density [kg*m-2*s^2], which is function of current ambient temperature,
pressure and humidity.

Hence Load [kg] = 0.5* Coefficient * Speed [m/s] ^2 * Density [Kg*m-2*s^2]

FRONT MAINPLANE

Design mainplane minimum HEIGHT (from reference plane) 72.5 mm

Mainplane angle is measured:
At the outboard end
On upper surface (placing a ruler on top of the flap)
From the reference plane (with zero rake)
Design mainplane INCIDENCE (relative to reference plane) 0.43° Nose-up

FRONT FLAP

Flap angle is measured:

At the outboard end (longer chord )
On the upper surface (placing a ruler on top of the flap)
Without wicker
From the reference plane (with zero rake)
Flap angle RANGE is 0° - 34° (Step 1°)
Nominal Flap WICKER HEIGHT 10 mm

“H” is meant with reference to the upper flap surface.

Pag. 49 di 63
FRONT ENDPLATE
Nominal endplate lower edge HEIGHT from reference plane is 50 mm

REAR LOWER MAINPLANE

Design HEIGHT (from reference plane) of the upper point of the trailing 422.8 mm
edge of the lower mainplane.
Lower mainplane angle is measured:
On the upper surface (placing a ruler on top of the mainplane)
From the reference plane (with zero rake)
Design lower mainplane INCIDENCE (relative to reference plane) 4°

REAR UPPER BIPLANE (for MDF, HDF and VERY HDF configurations)
Biplane angle is measured:
On the upper surface (placing a ruler on top of the assembly mainplane+flap)
Without wicker
From the reference plane (with zero rake)
Design top biplane INCIDENCE RANGE (relative to reference plane) 2°-25° (Step 1°)
Nominal Flap WICKER HEIGHT 10 mm

REAR UPPER MONOPLANE (for VERY LDF and LDF configurations)

Monoplane angle is measured:
On the upper surface (placing a ruler on top of the monoplane)
Without wicker
From the reference plane (with zero rake)
Design top monoplane INCIDENCE RANGE (relative to reference plane) 0°-11° (Step 1°)

REAR ENDPLATE
Maximum endplate TOP edge HEIGHT from reference plane is 933.5 mm

2013 AERO MANUAL

1. Rear wing packages

The rear top assembly can be fitted with or without the mainplane (biplane and monoplane
configuration respectively) depending on the downforce level. It is necessary to underline how the
maximum angle before the wing stall depends on the rear wing configuration, i.e. with or without
mainplane. A 10mm gurney on the rear wing flap is needed to reach the top downforce
performance.

Hereafter we will refer to three main configurations of the rear top assembly:

Rear top assembly Rear top flap add-

Configuration
airfoil elements ons
LOW DOWNFORCE Monoplane (flap only) None
MID/HIGH DOWNFORCE Biplane (mainplane + flap) None
VERY HIGH DOWNFORCE Biplane (mainplane + flap) 10mm gurney

Pag. 50 di 63
The following pictures show the angle references for front and rear wing adjustments as well as the
different options of rear top assembly with add-ons.

Angle references for front wing flap

A B C D E F G H
1 0° 1° 2° 3° 4°
2 5° 6° 7° 8° 9° 10° 11° 12°
3 13° 14° 15° 16° 17° 18° 19° 20°
4 21° 22° 23° 24° 25° 26° 27° 28°
5 29° 30° 31° 32° 33° 34°

0-10-10-0mm gurney on front wing flap 10mm gurney on rear wing flap

Pag. 51 di 63
 Angle references for rear wing top assembly (Biplane)

A B C D E F
1 2° 3° 4° 5° 6° 7°
2 8° 9° 10° 11° 12° 13°
3 14° 15° 16° 17° 18° 19°
4 20° 21° 22° 23° 24° 25°

Angle references for rear wing top assembly (Monoplane)

A B C D E F
1 0° 1° 2° 3° 4° 5°
2 6° 7° 8° 9° 10° 11°

Pag. 52 di 63
 2. Aerodynamic data

This section is dedicated to the aerodynamic data for the front and rear wing assemblies. All data
are relative to single ride heights (10mm/20mm) acquisitions with the exceptions of the aeromaps
that require 29 ride heights acquisitions. Each of the rear wing angle sweeps included in paragraphs
b and c are carried out at fixed front wing configuration, i.e. not balanced. The same approach is
adopted for the front wing flap sweep (paragraph a). Some balanced configurations are then
presented in paragraph d.

Definitions:

 Very Low downforce configuration:

 front flap without gurney
 front wing with turning vanes
 rear top assembly with monoplane configuration at 0° (without rear wing top
mainplane)
 rear top wing flap without gurney
 rear diffuser top trailing edge without gurney

 Low downforce configuration:

 front flap with 0-10-10-0mm gurney
 front wing with turning vanes
 rear top assembly with monoplane configuration at 0°-8° (without rear wing top
mainplane)
 rear top wing flap without gurney
 rear diffuser top trailing edge with 35mm gurney

 Medium downforce configuration:

 front flap with 0-10-10-0mm gurney
 front wing with turning vanes
 rear top assembly with biplane configuration at 2°-15° (with rear wing top
mainplane)
 rear top wing flap without gurney
 rear diffuser top trailing edge with 35mm gurney

 High downforce configuration:

 front flap with 0-10-10-0mm gurney
 front wing with turning vanes
 rear top assembly with biplane configuration at 15°-21° (with rear wing top
mainplane)
 rear top wing flap without gurney
 rear diffuser top trailing edge with 35mm gurney

 Very High downforce configuration:

 front flap with 0-10-10-0mm gurney
 front wing with turning vanes
 rear top assembly with biplane configuration at 21° (with rear wing top mainplane)
 rear top wing flap with 10 mm gurney
 rear diffuser top trailing edge with 35mm gurney

Pag. 53 di 63
 a. Front wing flap adjustment and wicker sensitivity

In the rear wing VERY LOW DOWNFORCE & LOW DOWNFORCE configuration (monoplane with
isolated flap) the front wing flap slope is:

Front Rear
Front Flap Front Flap Rear Top
Mainplane diffuser top CxT*S CzF*S CzR*S CzT*S Bal Fr %
Angle [°] Wicker Assembly
Add-ons T.E.
0 0.795 0.823 1.105 1.928 42.7
4 35 mm 0.807 0.866 1.077 1.943 44.7
0-10-10-0 Turning Monoplane
7 gurney 0.812 0.912 1.050 1.962 46.7
mm gurney Vane @ 11°
11 off 0.804 1.002 1.039 2.041 49.4
15 0.799 1.063 1.044 2.107 50.8

Front Flap Slope

1.100
15°
1.050

11°
1.000

0.950
CzF

7°
0.900
4°
0.850
0°

0.800

0.750
40.0 42.0 44.0 46.0 48.0 50.0 52.0

Fr Bal %

And the front flap wicker sensitivity is:

Front
Front Flap
Front Rear
Rear Top     
Flap Mainplane diffuser top Bal Fr
Angle [°]
Wicker
Add-ons T.E.
Assembly CxT*S  CzF*S CzR*S CzT*S
% 
0-10-10-0
35 mm - - - - -
mm gurney Turning Monoplane
0 gurney
Vane @ 11°
no gurney off -0.006 -0.020 0.014 -0.006 -1.0

Pag. 54 di 63
 In the rear wing MID DOWNFORCE, HIGH DOWNFORCE & VERY HIGH DOWNFORCE
configuration (biplane with mainplane and flap) the front wing flap slope is:

Front Rear
Front Flap Front Flap Rear Top Bal Fr
Mainplane diffuser top CxT*S CzF*S CzR*S CzT*S
Angle [°] Wicker Assembly %
Add-ons T.E.
5 0.919 0.799 1.719 2.517 32.0
10 0.916 0.883 1.697 2.580 34.4
15 0.916 0.958 1.697 2.656 36.2
20 0.920 1.053 1.667 2.721 38.8
35 mm 0.921 1.075 1.657 2.732 39.4
21 0-10-10-0 Turning Biplane
gurney
24 mm gurney Vane @ 18° 0.926 1.109 1.621 2.729 40.7
off
27 0.928 1.158 1.609 2.766 41.9
30 0.931 1.208 1.569 2.777 43.5
32 0.933 1.216 1.568 2.785 43.7
33 0.936 1.227 1.568 2.795 43.9

Front Flap Slope

33°
1.250 32°
30°
27°
1.150
24°
21°
20°
1.050
CzF

15°
0.950
10°

0.850
5°

0.750
30.0 32.0 34.0 36.0 38.0 40.0 42.0 44.0 46.0

Fr Bal %

And the front flap wicker sensitivity is:

Front Flap Front Flap

Front
Rear diffuser Rear Top     
Mainplane Bal Fr
Angle [°] Wicker top T.E. Assembly CxT*S CzF*S CzR*S CzT*S
Add-ons %
0-10-10-0 - - - - -
mm gurney 35 mm
Biplane
21 Turning Vane gurney
@ 18°
no gurney off 0.005 -0.103 0.093 -0.011 -3.7

Pag. 55 di 63
 b. Rear top wing in VERY LOW DOWNFORCE & LOW DOWNFORCE
configuration

The following table shows the aero data of the rear top assembly sweep in VERY LOW
DOWNFORCE & LOW DOWNFORCE configuration (i.e. monoplane with isolated flap).

Rear Top Front

Assembly Rear Top Rear Front
Flap Front Flap Bal Fr
Assembly diffuser top Mainplane CxT*S CzF*S CzR*S CzT*S
Angle Angle Wicker %
Type Add-ons T.E. Add-ons
[°] [°]
0 0.765 0.822 0.842 1.664 49.6
2 35 mm 0.780 0.823 0.962 1.784 46.3
0-10-10-0 Turning
Monoplane 4 None 0 gurney 0.791 0.824 1.046 1.870 44.1
mm gurney Vane
8 off 0.799 0.824 1.134 1.958 42.1
9 0.800 0.824 1.118 1.941 42.5

Rear Top Monoplane Slope

1.200

1.150 8°

1.100 9°
4°
1.050

1.000
CzR

2°
0.950

Complete
0.900 aero data
0.850 0°
The complete aero data over a map of 29 ride heights couples (all heights are full scale) are shown hereafter. The
0.800top assembly is the monoplane with isolated flap set to 8° without gurney, the front wing flap set to 0°
rear
without gurney, front main wing with turning vanes, without rear diffuser top trailing edge 35mm gurney.
0.750
0.760 0.765 0.770 0.775 0.780 0.785 0.790 0.795 0.800 0.805

Cx

Pag. 56 di 63
Pag. 57 di 63
 c. Rear top wing in MID DOWNFORCE, HIGH DOWNFORCE & VERY HIGH
DOWNFORCE configuration

The following table shows the aero data of the rear top assembly sweep in MID DOWNFORCE, HIGH
DOWNFORCE & VERY HIGH DOWNFORCE configuration (i.e. biplane with mainplane and flap).

Rear Top Front

Assembly Rear Top Rear Front
Flap Front Flap Bal Fr
Assembly diffuser top Mainplane CxT*S CzF*S CzR*S CzT*S
Angle Wicker %
Angle Add-ons T.E. Add-ons
Type [°]
[°]
2 0.836 1.131 1.231 2.362 48.1
5 0.855 1.128 1.308 2.436 46.5
10 0-10-10-0 35 mm 0.877 1.121 1.459 2.579 43.6
Biplane Turning
None 24 mm gurney
14 Vane 0.899 1.119 1.535 2.653 42.3
gurney off
18 0.926 1.109 1.621 2.729 40.7
20 0.935 1.101 1.643 2.743 40.2

Rear Top Biplane Slope

2.800
20°
2.750 18°

2.700

2.650 14°

2.600 10°
CzT

2.550

2.500

2.450 5°

2.400
2°
2.350

2.300
0.800 0.820 0.840 0.860 0.880 0.900 0.920 0.940 0.960

Cx

Pag. 58 di 63
Complete aero data

The complete aero data over a map of 29 ride heights couples (all heights are full scale) are shown
hereafter. The rear top assembly is the biplane with mainplane and flap set to 18° without gurney, the
front wing flap set to 21° with 0-10-10-0 mm gurney and front main wing with turning vanes, with rear
diffuser top trailing edge with 35mm gurney.

Pag. 59 di 63
 d. Balanced front and rear wings configurations

The following tables show some configurations of front and rear wings adjustments for the VERY LOW &
LOW DOWNFORCE, MID, HIGH & VERY HIGH DOWNFORCE configurations rebalanced @ Front
balance = approx. 40%. The link between the two tables is the configuration label indicated in the first
columns as well as in the final graph.

Rear Top Assembly Front

Rear Top Front
Downforce Rear Diffuser Flap Front Flap
Configuration Assembly Mainplane
Level Add-ons Angle Wicker
Type Angle [°] Add-ons Add-ons
[°]

1 VLDF Monoplane 8 None None 0 None Turning Vane

0-10-10-0
2 LDF Monoplane 8 None 35mm gurney 0 mm Turning Vane
gurney
3 2 8
0-10-10-0
4 MDF Biplane 5 None 35mm gurney 10 mm Turning Vane
gurney
5 10 13

6 14 18 0-10-10-0
HDF Biplane None 35mm gurney mm Turning Vane
7 20 25 gurney

0-10-10-0
8 UHDF Biplane 20 10 mm 35mm gurney 28 mm Turning Vane
gurney

Bal Fr
Configuration CxT*S CzF*S CzR*S CzT*S
%

1 0.794 0.799 1.151 1.950 41.0

2 0.810 0.836 1.171 2.006 41.7

3 0.837 0.902 1.356 2.258 39.9

4 0.856 0.943 1.427 2.371 39.8

5 0.878 1.003 1.567 2.570 39.0

6 0.902 1.119 1.619 2.738 40.9

7 0.944 1.275 1.671 2.946 43.3

8 1.019 1.300 1.696 2.996 43.4

Pag. 60 di 63
 BALANCED POLAR
Bal Fr @40%

VLDF LDF MDF HDF UHDF

3.250

8
3.000 7
6
2.750
5
CzT

2.500 4
3
2.250
2
1
2.000

1.750
0.750 0.800 0.850 0.900 0.950 1.000 1.050 1.100

Cx

e. Rear diffuser top trailing edge wicker sensitivity

This paragraph is dedicated to the evaluation of the effect of the addition of a 35 mm gurney on the rear
diffuser top trailing edge.

35 mm gurney on rear diffuser top T.E.

Rear Diffuser Add-ons     

CxT*S CzF*S CzR*S CzT*S Bal Fr %
35 mm gurney
- - - - -
on rear diffuser top T.E.

None -0.010 -0.016 -0.034 -0.050 -0.2

Pag. 61 di 63
Permitted / non permitted.

Aero configurations listed here above in this manual are the recommended configurations, any combination of
GP3 aero devices is permitted providing that :

 It does not contravene any limitation specified in the GP3 Technical regulations.
 Front flaps are fitted at all time (asymmetric front flap configurations are permitted).
 At least a rear top wing element is fitted at all time.
 10 mm gurney can be fitted on rear top wing biplane flap at any permitted angle of the biplane.
 Front flaps and rear top wing set up range are those permitted by any of their pre-drilled set up holes.
 Elements / devices are only fitted in a position described in at least one of the described configurations.
(i.e. an element can’t be fitted upside down - i.e. a rear top flap gurney can’t be fitted on the rear top
wing main plane etc….)

Pag. 62 di 63
 TECHNICAL BULLETINS

Date : 2013-05-09

Subject : Aero configurations - Clarifications

Should a car run in a configuration without front wing main plane underneath turning vanes, genuine
turning vanes fixing bolts must remain fitted (see picture here below).

Should a car run in a configuration without diffuser rear gurney, genuine diffuser rear gurney fixing
bolts must remain fitted (see picture here below).

When front flap or rear top wing gurneys are removed it is permitted to fill the gurney fixing holes
with filler ( i.e. silicone...).

Pag. 63 di 63