Bloodhound LSR
How to make a 1,000 mph carbon fibre cockpit
updated
After 10 years of research and development, a car was built that combined astonishing aerodynamics with a Eurofighter Typhoon jet engine. Bloodhound LSR.
The Bloodhound team had secured the perfect driver, current record holder, Wing Commander Andy Green, and they had located the perfect track, on a dried lakebed in the Kalahari Desert… they were ready to begin testing.
Then, in 2018, disaster struck, the project went into administration and Bloodhound was 24 hours away from being scrapped. But, Yorkshire businessman and engineer Ian Warhurst, chose to come out of retirement to save the project and see just how fast the car will go.
Building The World’s Fastest Car follows Ian and his team as they arrive in South Africa for six weeks of high-profile testing that they hope will attract sponsors to secure the future of the project, and prove that one day their car will smash supersonic, power past 800 miles per hour, and blast into the record books. It’s make or break for Bloodhound.
Rick Murray, MD of Workerbee, said:
“This is such a fascinating story and one we had to tell, so we actually started filming before we’d found a broadcaster who would take it. We’re really pleased that Channel 4 have come on board and we can’t wait for people to see the incredible effort the Bloodhound team have made while attempting this astonishing challenge.”
Ian Warhust, CEO of Bloodhound Land Speed Racing, said:
“Bloodhound LSR is a global endeavour to set a new world land speed record. By sharing this adventure with a worldwide audience, Bloodhound will help inspire the next generation about science, technology, engineering and mathematics, and will be a supersonic testbed for showcasing emergent digital technologies. We’re delighted WorkerBee and Channel 4 are championing our story to audiences across the UK.
Building the World’s Fastest Car will be distributed worldwide by Endemol Shine International
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...we went goat shopping.
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I’m the communications manager for the UK based team who designed and built the ultimate straight-line racing car. A team of 30 of us are here on the Hakskeenpan, in the Northern Cape, South Africa to put the jet powered car through its paces during a rigorous high speed test programme.
We’ve already seen the Eurofighter Typhoon jet powered car reach 501mph during the test programme, but today we’re aiming to test the air brake doors at around 350mph. The air brake doors are like huge carbon fibre elephant ears that stick out either side of the car; these generate drag (like sticking your hand out of the window of a moving vehicle) to bring Bloodhound LSR car to a safe halt.
Following a team briefing the car was towed out onto the Pan, a huge dried out lakebed 12 miles long and two miles across. Once positioned on the white line the Start Team set about plugging in the Air Start Cart (a small gas turbine used to start the car’s jet engine). The Air Start Cart cranked up and started blowing high pressure air but the jet engine refused to ignite.
It’s heartbreaking when, after many hours of meticulous planning and resolving some challenging issues over the last week, the run was cancelled and we had to return to Tech Camp to plug in the Systems Engineers and review the data. Crestfallen the team trudged back to their vehicles and we returned to base.
After several hours the source of the issue was identified (the DECU - Digital Engine Control Unit - failed to send a Start Request to the jet engine) and a software fix resolved it.
It’s now midday and temperatures are reaching the mid 30’s, so it’s a quick lunch and back out to the desert with the aim of making the two planned runs.
Under the searing heat the car was lined up on the line and plugged into the Start Cart. To everyone’s relief she fired up first time. A quick radio check with the Run Controller “Bloodhound is cleared to roll” and she’s off! First easing away under ‘max dry’ the jet engine spools up and Bloodhound rolls to 60mph in about 5 seconds before Andy puts his foot down and engages max reheat (aka afterburner). 20 feet of flame shoots out the back and with a visceral roar Bloodhound is off like a scalded cat, shooting to 200mph in a further 4 seconds and on to 353mph.
Andy then lifted and coasted to 100mph before applying the front wheel brakes to bring the car to a halt 7km down the track. What a great feeling it is when the plan comes together, the car works perfectly and another key Run Profile is crossed off.
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It was the sixth run down the desert for the car, which is being pushed faster each time by driver and current World Land Speed Record owner Andy Green.
The team is gathering vital data from each run to prepare the car for its World Land Speed Record attempt next year, when it hopes to break the current record of 763mph.
Andy said: “The aim of today was to measure the slowdown, from 500 down to 200, to measure the aerodynamic drag. We've got all that data, and now it’s time to crunch the numbers."
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Today’s ‘Run Profile 5’ called for a max reheat (afterburner) start from the zero-kilometre mark at the north end of the Hakskeenpan desert runway.
As well as pushing the speed further, a key objective today was to test the right parachute, after a successful deployment of the right parachute on the October 31st.
Andy Green rolled off the line in ‘max dry’ - no flames out the back - before picking the speed up to 50mph, at which point he pressed the throttle peddle past the detent catch, which engaged maximum reheat.
All of the Bloodhound’s 90kN of thrust (54,000bhp) was used to blast the car up to 461 mph. Andy had lifted off the throttle at 440mph to stabilise the car, before pulling the left parachute to test it is in working order.
As expected, the parachute took a second to deploy behind the car, before flying perfectly on its 20m strop (line).
Andy reported he could feel the parachute tugging rear of the car from side to side as it filled with air and increased the drag. The chute will be modified by removing ribbons two and four to see if will fly more steadily.
Once the speed had dropped to 150mph on the parachute, Andy applied the front wheel brakes to bring Bloodhound to a stop at the 9km mark.
As on the previous run, the ‘Rescue 2’ recovery team was quickly on scene to uncouple the parachute strop from the back of the car, which Andy then taxied on idle to the 16km mark at the south end of the track.
Here he performed a 240m diameter teardrop shaped U-turn to bring the car back to the adjacent track and ready for Run Profile 6.
Unfortunately, on inspection, the team identified a minor issue with the titanium skin on the rear deltas (the aerodynamic bodywork that covers the rear suspension). This caused the planned second run of 500mph to be aborted, and saw the car recovered to the Tech Camp for repair work.
Mark Chapman, Engineering Director, explained: "The issue was with an ‘into wind step’, which is an area of the bodywork that high speed air and desert grit blasted into as such a rate on this run, that it pealed back a corner, up to the first rivet. The Fabrication Team are trimming the 30mm long piece of titanium off before they bond and rivet a patch to cover the area.”
Today’s ‘Run Profile 5’ called for a max reheat (afterburner) start from the zero-kilometre mark at the north end of the Hakskeenpan desert runway.
As well as pushing the speed further, a key objective today was to test the left parachute, after a successful deployment of the right parachute yesterday (October 31st).
Andy Green rolled off the line in ‘max dry’ - no flames out the back - before picking the speed up to 50mph, at which point he pressed the throttle peddle past the detent catch, which engaged maximum reheat.
All of the Bloodhound’s 90kN of thrust (54,000bhp) was used to blast the car up to 461 mph. Andy had lifted off the throttle at 440mph to stabilise the car, before pulling the left parachute to test it is in working order.
As expected, the parachute took a second to deploy behind the car, before flying perfectly on its 20m strop (line).
Andy reported he could feel the parachute tugging rear of the car from side to side as it filled with air and increased the drag. The chute will be modified by removing ribbons two and four to see if will fly more steadily.
Once the speed had dropped to 150mph on the parachute, Andy applied the front wheel brakes to bring Bloodhound to a stop at the 9km mark.
As on the previous run, the ‘Rescue 2’ recovery team was quickly on scene to uncouple the parachute strop from the back of the car, which Andy then taxied on idle to the 16km mark at the south end of the track.
Here he performed a 240m diameter teardrop shaped U-turn to bring the car back to the adjacent track and ready for Run Profile 6.
Unfortunately, on inspection, the team identified a minor issue with the titanium skin on the rear deltas (the aerodynamic bodywork that covers the rear suspension). This caused the planned second run of 500mph to be aborted, and saw the car recovered to the Tech Camp for repair work.
Mark Chapman, Engineering Director, explained: "The issue was with an ‘into wind step’, which is an area of the bodywork that high speed air and desert grit blasted into as such a rate on this run, that it pealed back a corner, up to the first rivet. The Fabrication Team are trimming the 30mm long piece of titanium off before they bond and rivet a patch to cover the area.”
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Another hugely successful day of testing for the Bloodhound LSR team saw the speedometer swing to 380mph, plus the first deployment of the parachute which slows the car from high speeds.
During ‘Run Profile Four’ the Bloodhound car was started ‘dry’; without injecting the extra fuel for reheat. Once it hit 50mph World Land Speed Record holder Andy Green engaged full reheat (a.k.a afterburners) and piloted the car to 380mph (611kph). It took just 27 seconds, even though Andy lifted off the throttle when it hit 360mph.
At its maximum, the Bloodhound’s Rolls-Royce built EJ200 engine generated 90kN of thrust (c.54,000bhp).
Once the car hit the 2km mark Andy cut power completely and pulled Parachute One for the first time ever. The parachute was tugged from its canister by a drogue, a conical shaped device with open ends, which then deployed the full canopy, slowing the car until Andy used the front wheel brakes to bring car to a halt 3.8 miles from the start.
The recovery team - “Rescue 2” - arrived on site within one minute and released the parachute from the car. This is the process the team will use when making record breaking runs in 12 - 18 months’ time. It is crucial to ensure parachutes aren't dragged behind the car when it completes its transit down the length of the track, which is does before turning around ready for a return run within an hour.
An excited Andy Green said: "The video footage shows a clean release of the ‘chute behind the car, just one second after I pulled the release leaver. The engineering team and I are delighted all the hard work designing the deployment system paid off first time"
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Bloodhound started perfectly and blasted off down the white line, however, when she crossed the area where an old farmers track had been graded flat, there was a very minor bump that caused an engine stop switch to engage for under 10 milliseconds – causing the EJ200 jet engine to safely shutdown and aborted the run.
The car was recovered back to the Tech Camp where Bloodhound’s System Engineers poured over the data and identified the issue. The data was verified by checking the video footage from the rear facing fin camera. This clearly showed the engine cutting out as the car crossed the darker coloured patch of desert. It was so quick that Andy Green couldn’t feel it from the drivers seat.
The Systems Team, lead by Joe Holdsworth, are confident that their software modifications will make the switch less sensitive and ensure the high speed test programme continues as planned.
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We should be on track to do a 100mph run tomorrow!
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However, the start up cycle took four seconds longer than the 60 second start process and automatically shut down - as it's designed to. We're confident next time out it will run without issue. Nobody said land speed racing would be plain sailing!
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20h
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A dry crank test is a crucial stage of the pre-testing programme as it confirms the engine and all its ancillary systems, fuel and electrics are correctly installed and ready to fire up once the car is in the full system test, confirming the engine can be started.
To perform the test the team will used an Air Start Cart (a small jet engine) to blow high pressure air into the onboard Aircraft Mounted Accessories Drive (AMAD) gearbox, which will both spin the jet’s turbine up to required speed and, once spinning, generate 3-phase AC power for the car, which then sends power to the jet engine’s fuel pumps.
The new name, Bloodhound LSR, accompanies a complete rebranding of the programme. This includes a visual transformation of the car, which was revealed in a new striking red and white livery as she moves into her new home at SGS Berkeley Green University Technical College (UTC) on the Gloucestershire Science and Technology Park.
Grafton LSR Ltd CEO Ian Warhurst said: “Since buying Bloodhound from the administrators last December, the team and I have been overwhelmed by the passion and enthusiasm the public have shown for the project. Over the last decade, an incredible amount of hard graft has been invested in the project and it would be a tragedy to see it go to waste.
“Starting with a clean slate, it’s my ambition to let Bloodhound off the leash see just how fast this car can go. I’ve been reviewing the project and I’m confident there is a commercial business proposition to support it. I’ll provide robust financing to ensure there is cashflow to hit the high-speed testing deadlines we set ourselves.”
New headquarters
The UK Land Speed Record Centre at SGS Berkeley Green UTC provides a 975 square metre workshop facility in the heart of the college campus, fulfilling Bloodhound’s promise of delivering educational inspiration.
SGS Berkeley Green UTS group chief executive and executive principal Kevin Hamblin said; "We're excited that Bloodhound is joining us at Berkeley. To have such a groundbreaking engineering project on site which shares our philosophy to enthuse and encourage the next generation of engineers, designers and scientists, will be invaluable for our own students and also for thousands of young people across the region who will have an opportunity to visit the Gloucestershire Science and Technology Park over the next few years and see the car for themselves."
Team list
The Bloodhound LSR team is headed up by Ian Warhurst. Ian is joined by driver and current world land speed record holder Andy Green, engineering director Mark Chapman, chief financial officer Rick Sturge, operations director Martyn Davidson, commercial director Ewen Honeyman, and many of the original mechanics and technicians, providing continuity from the old programme to the new.
Former CEO Bloodhound Programme Ltd Richard Noble, said “It was a very hard fight to create the Bloodhound car, the largest STEM programme in the UK, the public engagement programme and the 1,000 man year desert preparation. Our weakness had always been finance and now after Administration, with Ian Warhurst the team finally has the financial support it needs to drive forward with confidence and achieve what we set out to do nearly 12 years ago.
Sponsorship and branding
The Bloodhound LSR car’s bare red and white livery is likely to change once the sponsorship team’s discussions over title branding opportunities with interested parties reach fruition. The iconic blue and orange livery from the R&D phase will live on in photos and film.
Grafton LSR commercial director Ewen Honeyman said: “With Ian providing the cashflow to keep the project on track, Bloodhound LSR is a very different sponsorship proposition to the blue and orange car. We’re already having detailed discussions with a number of organisations about exciting new sponsorship possibilities, as well as talking to those involved in the previous phase of the programme.”


