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Team Magic E4RS4 Concept:

Designing the Team Magic E4RS4:

What adventure we lived there ! To create the Team Magic E4RS4 turned out to be a challenge as great as passionant. Strong from our great and fruitful passt experience of the developement of the Team Magic E4RS II Evo, E4RS III and E4RS III+ cars, Team Magic Taïwan gave the responsability to create and design the E4RS4 to Team Magic Europe. So, I worked hard on the conception of the car, while Jeremy Clavey, professional CAD draftsman, designed the parts. This first collaboration with has been extremelly professional and pleasant, and I deeply thank him for that.

The E4RS4 is the result of a long work of study, drawing and numerous discussions with the Team Magic drivers of whom I'm in charge of here in Europe, as well as very invaluable advice of a world level driver (top ten), further to the test the E4RS III+ in a intensive way last year. Each of them had the possibility to express their opinion, to suggest ideas and to talk about their experience. I thank all the drivers for their precious help, as well as for their results and involvement.

In order to create the E4RS4, we studied in depth the weak points of the E4RS III+. We defined four axes of improvement to create the E4RS4.

  • Lowering the centre of gravity and reducing the global car weight.
  • Reducing the longitudinal flex.
  • Optimising the torsionnal flex, as well as the "Symetric Flex" concept.
  • Improving the efficiency and stability of the settings.

So, all the central part of the car has been rethought: chassis, upper deck, bulkheads, position of them, motor and middle axle mount, servo mount and flex management.

All this with the aim of improving an already very successful base, that was the E4RS III series.

To close this introduction, I would thank once again the Team Magic drivers, of all levels; as weel as the staff of Team Magic Taïwan, and also Jeremy Clavey, for their collaboration which I appreciate quite particularly.

Lionel Troyon - designer of the Team Magic E4RS4

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Chassis:

Team Magic was a precursor in matter of symmetric flex, by being the first brand to mill the chassis under the battery, identically to the milling under the motor. Obviously, we maintain this key element, which has been largely be used by almost all of the brands; and we improve again our concept by centering perfectly the servo mount and by re-centering drastically the motor mount and the right middle axle mount.

For the E4RS4, we chose a chassis in High Grade 2.3mm graphite, which corresponds better to the flex obtained by the various elements which take place on the chassis (bulkheads, motor mount, servo mount etc.).

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Upper deck:

The E4RS4 upper deck, made of High Grade 2.0mm graphite, is entirely new: we reduced the distance between the fixation screws to improve the the torsional flex management and revised its design over the bulkheads.

Obviously, it is also perfectly symmetric and contributes to the "Symetric Flex" concept.

Thanks to a better flex management, we were able to lower the deck by 2mm, to contribute to the general masses lowering.

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Flex optimisation:

The overall flex of the chassis has been entirely revised in order to improve the car handling at all levels.

For that purpose, we decided to act on both type of flex in a different and totally different way.

The torsional flex and its symmetry are improved, by narrowing drastically the bulkheads and middle axle mount, as well as by redrawing completely the servo and motor mounts.

The longitudinal flex, which we could call "bad flex", is minimized, by lengthening bulkheads and by creating an adjustable central flex plate between the servo and motor mounts.

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Motor mount with flex management:

On the E4RS4, the design of the bloc constituted of the motor mount and the middle axle mounts is completely new; and allows from now a precise management of the flex of the car.

And this, while minimizing at the most the impact of the block on the torsional flex of the car by reducing radically the width of its base by re-centering the fixation of supports to the chassis directly under belts; key element of the E4RS4.

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One-piece motor mount:

We completely revised our motor support, which passes from five parts to only one !

The concept of the motor mount is multiple:

  • Reduce the impact of the motor mount on the chassis torsional flex.
  • Eliminate any risk of tweak coming from the motor mount.
  • Reduce the car weight significantly.
  • Lower the center of gravity.

We are very proud of the result: thanks to an inovative and original design, our motor mount reached perfectly alls the determined objectives.

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Central layshaft mount:

In order to perfectly complete the job made on the motor mount and left middle axle mount, which are now only one piece, the right middle axle mount have been redesigned and its fixation is now closer to the centerline of the car and to the spur gear.

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Lower bulkheads:

The lower bulkheads of the E4RS4 are also completely new. Lower, narrower and re-centered to lower the center of gravity and improve the torsional flex.

They are also longer, to reduce the longitudinal flex, and have 3 fixations to the chassis plate which it is possible to mix to set more finely the flex.

They also directly support the anti-roll bars via a ball bearing system (like on the E4RS III series).

Note that these parts are the same on front and rear, to minimise the number of spare parts.

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Upper bulkheads:

The upper bulkheads of the E4RS4 are also new. They have been designed in the same spirit of flex optimisation.

Combined with the new shock towers, they allow to chose between a solid left/right link with 4 screws, medium with 2 screws and 2 guides, or less rigid with 2 screws only.

As with the lower bulkheads, the upper ones are also the same on the front and rear to minimise the spare parts.

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Suspension arm holders:

The system of arm mount, which widely showed its ability on the E4RS III series, has been kept on the E4RS4.

To avoid to require a multitude of different arm mounts, to adjust the width and the arm angles, we choose to use a system of inserts with hard treated aluminium pivot balls allowing a ultra fine and precise setting .

Optional arm mounts allow users to optimize the setup according to the diverse types of track.

The front "+2" arm mounts are now included in the kit, in purpose to optimise the front end handling on most of the circuits.

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Suspension arm holder inserts:

To adjust very finely the arm position on the lateral plan, we use arm holder inserts allowing a variation of 0.2mm.

Three inserts allows 5 positions:

  • Centered
  • Excentered by 0.2mm (-0.2 in / +0.2 out)
  • Excentered by 0.4mm (-0.4 in / +0.4 out)

The inserts of E4RS4 are the latests reinforced models.

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Aluminium pivot balls:

To strengthen this tender spot and guarantee a perfect liberty of movements, the arm pivot balls of the E4RS4 on hardened Aluminium.

This provides lightness, precision, liberty and solidity to the assembly.

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Suspension arms angles:

This is definitely the most worked aspect of the E4RS III and E4RS4. For this, we decided there to offer the finest settings available on the market, among the cars using this kind of conventional arm mounts.

For that purpose, we created 3 RF/FR mounts and 3 FF/RR mounts. Please note that the supports are the same for font and rear, in order to minimize the number of parts.

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High precision roll center adjusters:

In order to obtain an easy and ultra-fine setting of the roll center, we developed these ultra-precise spacers, which are very easy to insert between the chassis and arm mounts, without removing screws.

These spacers exist in 3 thicknesses: 0.1mm, 0.25mm and 0.5mm.

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Hard coated suspension shafts:

The suspension shafts are hard coated polished steel, in order to ensure perfect alignment and movements without any hard points.

The outer shafts feature a flat spot in order to ensure a perfect grub screw fit on both the front caster blocks and rear uprights.

Please note that we decided to use same inner axles for front and rear, to minimize the number of parts.

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Reinforced C-hubs:

The C-hubs of the E4RS4 are the reinforced models, released in 2016 for the E4RS III+, to increase their durability.

All the plastic suspension parts of the E4RS4 are the graphite reinforced versions in order to provide more rigidity and precise control of the suspension movements.

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Modified steering blocks:

The E4RS4 features the latests front steering blocks, that provides an increased steering angle; released in 2016 for the E4RS III+.

Since the first E4RS II, the Ackermann has tree positions on the wheel side, for a finer setting.

This parts are higly loaded in graphite.

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Zero-Play suspension arms:

The E4RS4 is delivered with new "Zero Play" front and rear arms, especially released in 2016 for the E4RS III+. Obviously, these parts feature a high ratio of graphite for a perfect stiffness.

The driver can now adjust himself the liberty of movement with an arm reamer.

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Anti-roll bar mounts:

Team Magic has been precursor in the domain of anti-roll bar ball-raced fixation; which was already existing for the E4RS II five years ago as optional part.

For the E4RS4, it was completely logical to keep this system which works perfectly.

Please note that the pivots are now black anodized, for a even smarter look.

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Aluminium 7075 Black pivot ball:

To reduce weight, the E4RS4 is delivered with aluminium 7075 pivot balls.

The new smart color perfectly match the "all black" E4RS4 design.

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Aluminium 7075 Black turnbuckles:

We decided to deliver the E4RS4 with new, lightweight, black anodized aluminium 7075 turnbuckles.

Like for the pivot balls, the new color perfectly match the "all black" E4RS4 design.

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Aluminium 7075 spur gear holder:

The ultra-light spur gear holder received a hard treatment.

The fixation by three screws aims to be at the same time safe and light.

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CNC machined Delrin spur gear:

Team Magic includes a Kfactory CNC machined Delrin spur gear !

Two crucial advantages to this:

  • Delrin is a material with very low coefficient of friction and wear.
  • A machined spur gear is always perfectly round, unlike the moulded ones.

This is top quality part provided by Team Magic with its E4RS4 kit.

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"Low Friction" BANDO belts:

Belts provided by Team Magic are now "Low Friction" BANDO models, ensuring an extreme freeness and smoothness of transmission on the E4RS4.

Team Magic chose the Japanese leader of the manufacturing of transmission belts, rather than turn to low-cost suppliers, as to once again to ensure a quality of the highest level.

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Belt tension eccentric adjusters:

Team Magic chose to colour their belt tension eccentric adjusters in orange; not to look pretty, but to stand out visually of the black bulkheads and to allow to users to check which tension notch is the eccentric positioned at a quick glance.

Orange being the basic colour of the Team Magic logo, the colour contrasting perfectly with black was quickly found.

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Front spool with steel outdrives:

The E4RS4 is delivered with a front spool featuring new hard coated steel "No Blades" outdrives, which significate without plastic inserts between the driveshafts and the outdrives, to favor the corner speed.

The steel outdrives allows the use the most powerful modified motors without any problems of durability. It is an undeniable advantage for a competition kit.

The main part of the spool is machined in hard treated 7075 hard Aluminium, for the highest possibly reduction in weight.

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Gear differential with composite gears:

The E4RS4’s differential is composed by 4 moulded composite satellite gears. This ultra compact differential is very light and efficient.

The double gasket system ensures the differential’s perfect seal and the diff case is moulded with four unclosed screw holes in order to avoid any negative pressure under them for a greater durability of the screw thread in the main differential case.

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Front double-jointed driveshafts:

The front driveshafts delivered with the E4RS4 are double-jointed and machined in hard treated steel. They are also "No Blades" version, which significate without plastic inserts between the driveshafts and the outdrives, to favor the corner speed.

We didn't only removed the blades of the driveshafts; because the 2mm pins represented a too big factor of wear. We thus chose to use 3mm pins, more durable and less agressive for the spool outdrives.

The double-joint system allows higher angles of steering and greatly reduce the "chatter" that the front drivetrain generates with standard CVDs.

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Rear driveshafts:

The rear driveshafts are lightened steel models, without grub screw to maintain the pin. Indeed, the grub screw sometimes caused problems, contrary to the front double articulated driveshafts.

We therefore used the same principle of retaining the pin with a G-clip than used on front double-joints, which also has the effect of making the articulation more free and constant.

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Floating steering system:

The excellent floating steering system of the E4RS III has been kept on the E4RS4.

This system allows to minimize at the most the influance of the steering system on the chassis flex.

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Optimized steering plate:

The steering plate of the E4RS4 has been improved again at the level of the position of the steering pivot balls, thanks to the excellent work of the pilots of the team.

So, the Ackerman of the E4RS4 (difference of angle between the internal and outside wheels of the curve) has been optimized, to increase the corner speed.

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Floating servo mount:

The E4RS II EVO and E4RS III’s excellent one-piece floating servo mount has always been an important part of the extreme precision of the car.

However, we improved again what was already considered as one of the best servo mount of the market, by integrating it into our concept of "Symetric Flex". Indeed; on the E4RS4, its fixation is from now on the absolute center of the car.

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Ultra stiff servo ballcup:

Team Magic was the first manufacturer to dare an angled steering servo ballcup on the 3-Belt E4RS, 10 years ago.

The model chosen for the E4RS4 is perfectly stiff and solid, to offer a perfect precision and constancy of the steering.

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Ultra stiff shock towers:

To lower more the center of gravity of the E4RS4, we drew new "Ultra Low CG" shock towers; and to optimize the work of the shock absorbers, we chose to make them ultra stiff.

These towers are made in High Grade 3.5mm Woven Graphite, a guarantee of rigidity and solidity.

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Shock absorbers:

The E4RS4's shock absorbers hare completely new:

  • New Teflon coated and polished big bore shock body
  • New LRS (Low Rebound System) shock cap
  • New Teflon piston shaft guides
  • New spring setting collard with visual cue
  • New shock membrane
  • New Teflon big bore piston
  • New hardened and polished shock shafts

These new shock absorbers are also ultra-short, in purpose to lower the center of gravity ("Ultra Low CG"), while allowing the use of 25mm springs, what only Team Magic realised.

All this provides a better smoothness of movement, and a wider range of ride height setting.

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Low rebound system shock caps:

The E4RS4 shock caps feature the LRS system (Low Rebound System) which minimizes rebound, while keeping a precise and reliable architecture of the shock absorbers.

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Teflon coated big bore shock bodies:

The new E4RS4 Big Bore shock bodies features a Teflon coating and mirror finish on the internal surface.

This provides an unequalled smoothness and quality of movements.

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Hardened and polished shock shafts:

The hardened and polished shock shafts provide an excellent durability as well as a constant free movement.

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Big Bore Teflon shock pistons:

The new Big Bore shock pistons are machined in high quality Teflon to obtain perfectly free suspensions movements.

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Shock shaft teflon guides and O-rings:

The small shock piston shaft guides are machined in Teflon.

They perfectly complete the new shock bodies in term of smoothness of movement.

They are completed by silicon O-rings of high quality.

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Shock spring setting collars:

In order to make the ride height setting easier, the shock spring setting collars now features a visual mark.

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Shock spring cups:

While having one of the shortest shock absorbers of the market, our Aluminium spring cups allow to use long shock springs (25mm long), which provide you the possibility to use a large range of springs.

This allows to stay in an adequate ride height range (4.5~5.5mm).

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Team Magic Pro Touring matched shock springs:

The springs provided with the E4RS4’s dampers of the famous Team Magic Pro Touring matched springs of 22.5mm length.

The P2.6 springs feature 6 coils made with 1.4mm wire, which is a common choice for the rear; while the L2.7 front springs feature 7 coils, they are made with a 1.5mm wire, which are a perfect complement of the rear springs.

This choice of springs provides a good handling on tracks with a medium level of grip.

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Aluminium 7075 wheel hex adapters:

The E4RS4's wheel hex adapters are clamp type and machined in 7075 Aluminium.

The clamp type hex adapters avoid any undesirable play around the pin which would could force and restrict the wheel hub at high stresses.

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Optimized battery position and mounts:

The E4RS4 battery location has been optimized.

The central guides perfectly maintains the battery in place on the center of the chassis, without interfering the flex movements.

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Quick release battery holder:

The E4RS4 also features a quick release battery holder with a Velcro strap.

The Velcro strap perfectly holds the battery in place in its retainers without forcing or over stressing the assembly, and provide the huge advantage to not influence the flex of the chassis plate, contrary to a basic fixation with fiber tape.

This fixation is also a more economical and ecological solution compared to fiber tape.

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Battery retainers:

The battery retainers allow the battery to maintain perfectly positioned both laterally and longitudinally on the chassis without interfering in the chassis flex as do certain alternative retainers (notably systems with screws on the servo and motor mounts).

The retainer plates are machined in High Grade carbon and are adjustable in three longitudinal positions.

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Low Friction ball bearings:

The ball bearings delivered with the E4RS4 kit are Low Friction.

They are also supplied lubricated with oil, instead of grease, for increased transmission freeness.

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Heavy duty body posts:

The E4RS4’s body posts are heavy duty with a 6mm diameter. They offer great stability and rigidity of the body fixings.

The body height is, of course, adjustable in a precise manner.

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High density foam bumper:

The nylon bumper plate is supplemented with a high-density foam with respectable thickness, in order to better preserve your material in case of crash.

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English texts: Lionel Troyon with the kind assistance of Dominique Tranquille for some texts. Pictures: Lionel Troyon and Team Magic.
Last update 19/01/2025
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