DJ Wilmas 111S S2 Lotus Elise, turbo k seriesdjwilma |
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 Expert Posts: 2812    Location: Bournemouth | As you all know i sold the engine in the Metro to Daz so he can be the first to be over 300bhp and with the cash i told my pregnant wife we needed a new family car so i bought this 2005 Cat C Elise 111S the last of the k series powered cars (160bhp on lotus management)  I am hoping to build it on a budget less than the price of a straight low mileage 111S after using the knowledge from the metro Needs a little work and its with the infamous Cheeky Scott we will get it put back together and re-sprayed black. There is no chassis damage just front and rear clams and a few minors repairs Plan is to get the car back on the road with the std engine, whilst building the turbo block I thought long and hard about what engine to use, i was tempted by the VAG and T series but ultimately for me they are too heavy with the S2 already being over 800kgs. Honda just doesnt appeal to me (sorry Munday) and i have asked drew at Roverdose to build the engine..... Engine spec will be as follows DKE 79.4mm Forged Crank Wossner Pistons 80mm (but i have some 82mm so we will see) Wossner custom Rods VVC Head, ported and polished 32.4mm inlets 28.5mm exhaust Paul Ivey Valves, double springs, caps and solid followers Cams 270M Exhaust 285M inlet (may go custom or Newman PH2 will see) Custom Equal Length 1 7/8" Exhaust Manifold T25 flange GTX2860 turbo Siemans 660cc injectors AP Racing 220 Turbo clutch (good for 300lbft) W4 Uprated PG1 steel caged with Quaife Diff Charge cooled (more likely a custom Pro Alloy) Vibratechnics uprated engine gearbox mounts DTA Pro S80 with traction and launch control Going to go for 350bhp + will be happy with 300bhp but we will see what happens Suspension and Brakes will be uprated to suit, yet to decide but we will see Front damage, its missing the front crash structure, now bonded on  Front damage, its behind the clam so not an issue  Driver doors, need some repairs  DKE Crank, of unknown origin...79.4 stroke (we hope)  82mm forged pistons  after a day at cheeky scotts    | ||
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 Elf eating dog breeder Posts: 10531   Location: Guildford | |||
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 Lotus powered R100 MP Admin  Location: Torbay, South Devon, UK | Family car  | ||
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 Expert Posts: 8490 Location: Midlands | |||
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Expert Posts: 2812 Location: Bournemouth | Mutts - 17/4/2012 5:56 PM Family car We talked and agreed the nanny can take little one in the alfa  | ||
| Jim VVC |
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 Expert Posts: 3783 Location: Studley, Warwickshire | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 3783 Location: Studley, Warwickshire | Yes I read that lol, seems a character  | ||
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 Transport Guru MP Moderator Posts: 4947 Location: Bromley, Kent | I'd like one of these, with the 160 K series. K series have a nice engine note [4-5k] and I don't think a loud exhaust is needed. If a K series engine cover isn't needed... | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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 Expert Posts: 2029 Location: sittingbourne, kent | Looking good, some quick progress! Look forward to beating you again at santapod  | ||
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 17/4/2012 8:55 PM Looking good, some quick progress! Look forward to beating you again at santapod if you do i will stick a R65u and a 1.8 turbo engine in it | ||
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Expert Posts: 2029 Location: sittingbourne, kent | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Took the door off today and it looks like it is beyond repair which is a sod, will have a better look later Got some Paul Ivey valves today 8 off 28.5mm exhaust valves 8 off 32.5mm inlet valves I have a Polished and Ported VVC head that i am going to use but will be off to Rog at Sabre to have a look and give it a little fettle Spoke with Newmans Cams today and sent them the spec so we will see what they come back with regarding Cam design   | ||
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 Extreme Veteran Posts: 592 Location: kent | |||
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Expert Posts: 2812 Location: Bournemouth | Steve Butts has one on his elise and it sucks power, he only gets 302bhp ! Speak with Drew if your going to do it in the future he has plans in his head that make mine look boring | ||
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 MP Admin Posts: 17870 Location: Gloucester | |||
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Expert Posts: 2812 Location: Bournemouth | Metromartin - 20/4/2012 8:17 PM Very nice. Like those wheels alot, i got the heavier 6 spokes on mine. really want to get a 111S rear diffuser for mine, i'm tempted to get the short roof aswell like you have as it would fit in the boot better. Martin the engine loom and box will be for sale soon I want a hard top but free Louise they go four silly money What tyres do you use ? | ||
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MP Admin Posts: 17870 Location: Gloucester | djwilma - 21/4/2012 8:40 PM Metromartin - 20/4/2012 8:17 PM Very nice. Like those wheels alot, i got the heavier 6 spokes on mine. really want to get a 111S rear diffuser for mine, i'm tempted to get the short roof aswell like you have as it would fit in the boot better. Martin the engine loom and box will be for sale soon I want a hard top but free Louise they go four silly money What tyres do you use ? I've recently fitted Toyo T1R proxies to mine but it had continentals on before, the tyre walls are really soft on the T1Rs (which i also have on my metro VVC and my rover600turbo and liked them hence why I got them again) They will do for me but having a car which is fouced on handeling so much shows how important tyres can be to the feel of the car! They were about half the price of what tyres I had on before as i'm running standard 1.8 118hp engine went for it but didn't expect how different the car feels in the corners. I've got used to it now and still can press on well and they are good in the wet. On Seloc theres endless tyre threads and the seloc techwiki pages are very good. I was thinking about a hard top, but the £500 to 1k asking price I havn't bothered! even replacement rag top goes for £300 to 500. I'm tempted to get a short top roof as the long one takes up most of the boot space and has 2 extra catchs to undo when removing it. I've also smashed the bottom of my front clam on mine so if you ever see a black S2 clam i'm after one. I've just bought a front splitter to cover the holes! TBH i spent most of my hard top budget on the US spec LED rear lights so all 4 rear lamps act as tail lights I havn't got any fog lamps at the moment but I refitted my standard lamps for MOT time as i'm going to buy a S1 elise rear fog lamp for it. I also changed the side repeaters for astra mk4 items the last S2/exige which I got from the local scrappy, straight swap but your might have those already. | ||
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Expert Posts: 2812 Location: Bournemouth | Thanks Martin Drew at Roverdose has stripped the 1.4 spi engine i gave him and the good news is it is the damp liner block which should help with strength  Jonathon at JDM Dyno has kindly made an exhaust turbo manifold for Tinytim on here and i asked for a jig to be made so he will be making a second one for me It looks a tight squeeze but should be able to get everything in and will cut the panel behind the drivers seat to get the turbo in Turbo will be a GTX2860 and will be ceramic coated as will the exhaust to keep heat down. .jpg) _0.jpg) _0.jpg) Edited by djwilma 29/4/2012 10:10 AM | ||
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Expert Posts: 2812 Location: Bournemouth | Did some sums today and the wife then re-did them properly Long of the short is the lotus will be staying std with only 156bhp......dont know how i will fair with it now but the wife says i cant spend anymore money so, as i wear the trousers, i agreed with her Aparrently divorce would cost me a lot more  All seriousness having a kid so have to be sensible.....shame as i really wanted 400bhp / tonne Have sold most of the bits so just had to own up to myself ! | ||
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Expert Posts: 2029 Location: sittingbourne, kent | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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 Metro Mad Posts: 7653 Location: Tamworth, Staffs | ding - 9/5/2012 10:14 AM I put that post in here rather than in a txt (as its cheaper) oh no your walking with a squeak again | ||
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Expert Posts: 2812 Location: Bournemouth | R119GTA - 9/5/2012 2:52 AM ding - 9/5/2012 10:14 AM I put that post in here rather than in a txt (as its cheaper) oh no your walking with a squeak again I laughed when I saw that this morning ding back tracking........bring back the old ding | ||
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Expert Posts: 2812 Location: Bournemouth | So glad when we got married we agreed to have seperate bank accounts Have bought a VX220 turbo intercooler which i will mount in the drivers side pod and get some side scoops to help air flow  Also managed to find a nice Ported and Polished Head with 32.5mm inlets and 28.5mm exhaust valves and mechanical followers. Cams are 1227 which would be a little wild for the turbo but i may use the inlet cam and get a custom high lift low duration for the exhaust 10.5mm and 260 degrees for example.   Idea is to get the STD 1.8 turbo (for the mini) into the car with an intercooler, get the mems 3 up and running whilst buying bits as i go for a high power rover k series. This may change on whether the wife finds out, loses her job, kills me or baby comes early Oh and Wayne at Pro Alloy kindly sent me a triple pass radiator Spent most of today sorting out the heating, heater matrix and blower as the car has been sat for 4 years they have all corroded up. All working now Lights were a bugger had issues with the light control module blowing, a lose connection and also an open circuit. Been frustrating few days but all working and hunky dorey now ! Edited by djwilma 22/6/2012 6:02 PM | ||
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Expert Posts: 2812 Location: Bournemouth | Ok some of you may have seen that all my k series stuff has been up for sale Basically i tried as best as i could to get the k to over 350bhp, but everyone that has gone to this level other than the 1.4 boys have had issues so i just couldnt take the chance. Thats not to say its not possible but i dont have the time and money when i had the metro to buy, try and fix. So i sold everything in a bid to raise some cash for a new engine. This has been done to an elise before but only as std spec and they are quick then, but i have bought a forged T series, well pistons and rods, and in this spec with the right turbo they are good for 500bhp+ This one has a GT3076R turbo and custom manifold but neither will fit the elise and i dont want nothing / everything so changing a few things. ECU is an E48 DTA but will be going S80 so i can have traction control (elises swap ends easily and i havent had a RWD car since i was 17, and i crashed that...twice)   Power Curve with the current setup  Bought some bits from Grant at www.gb-ent.com GTX2867R 0.64a/r turbine housing should be a nice and quick spool actuator 12psi Gizzmo MS-IBC to control Boost MTX Wide band controller Water pump flange, goes onto block for electric water pump Davis Craig EWP 80lpm with controller T Series exhaust flange, to add to K series manifold Collected engine today from Chelmsford after work so tomorrow evening i have a go at squeezing it in, mainly as i have no room at the moment  Edited by djwilma 26/7/2012 10:07 PM | ||
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 Mr Bodge It Posts: 1303 Location: Tamworth, Fazeley | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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 Track Slag Posts: 5060 Location: Washington | |||
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Expert Posts: 2812 Location: Bournemouth | Ding, they aint seen nothing yet Engine is out of the Alfa, which needs a clean, and its now at the lock up with the lotus. Removed the manifold that was on there today as it just wont fit in the Lotus, the turbo a small GT3076R was also removed  Here is the difference, the old 160VVC engine next to the T series....  Cheeky Scott, Bournemouths finest panel beater holding up the turbo and manifold which i have sold with the loom and E48 ECU already to cover the cost of the GTX  Then when i was home i got the k series manifold out and checked it against the T series one from www.gb-ent.com should fit.  Ordered bits yesterday and they arrived today, nothing like good service from Grant. Turbo should be with me Thursday so i can look at getting a trial fit against the bulk head  Edited by djwilma 27/7/2012 5:13 PM | ||
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Expert Posts: 2812 Location: Bournemouth | Well the engine is in the car, gearbox mount is on but the cam cover side of things is a little bit of a bugger The aluminium mount is touching the plastic cam cover  But as said the engine is in and not too bad a fit   There is a little bit of room for the manifold and turbo to be fitted  When i got home today also had a couple of goodies waiting for me, the ECU DTA S80Pro and the GTX2867 turbo oh and a reminder i only have 8 weeks to finish the car off     This is the compressor curve for the GTX it is supposed to spool a little quicker than a disco potato and flow as well as the GT2871 and stay efficient above 2 bar boost !  Edited by djwilma 1/8/2012 7:56 PM | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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 aka chris_evz Posts: 2726 Location: brynna south wales | |||
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Expert Posts: 2812 Location: Bournemouth | p319 hok - 1/8/2012 4:22 AM MUCH MORE IMPORTANT DYLAN HAS AN ANDREX PUPPY !!!!!!!!!!!!!!!!!! she is 13 and has no lower jaw hence why the tongue hangs out, did have another one but he is in the kennel in the sky.....shame he would of loved the elise Edited by djwilma 1/8/2012 9:09 PM | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | Awww, didnt even notice, howd that happen ? How does she eat food ? Cute though ! She got a pink collar like you ? | ||
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Expert Posts: 2812 Location: Bournemouth | p319 hok - 1/8/2012 5:57 AM Awww, didnt even notice, howd that happen ? How does she eat food ? Cute though ! She got a pink collar like you ? It got cut off by the vet, using her mouth, she is, she did and it had diamonte's as a puppy but she needed a more agressive look when we got the other one | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | So shes still got some of her jaw then ? Hahaha pink with diamontes so you and her matched ? How much of the elise needs painting ? | ||
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MP Admin Posts: 17870 Location: Gloucester | |||
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Expert Posts: 2812 Location: Bournemouth | Engine mount was made today, used the existing 620 turbo mount and modded to suit the std elise one Will see how this gets on as the std mount is not known for its torque holding capability but the vibratechnics ones are Thanks for comments so far  | ||
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 Expert Posts: 5629 Location: Letchworth/Basildon | Which will be finished first, baby or Lotus?! | ||
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Expert Posts: 2812 Location: Bournemouth | munday - 5/9/2012 12:03 AM Which will be finished first, baby or Lotus?! baby, but best man just bought a WRX Scooby and a Caterham Superlite and has been texting me photos of him at track days i should of been going to (in the metro) so may get a move on with the elise | ||
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| Elite Veteran Posts: 697 Location: leigh | |||
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Expert Posts: 2812 Location: Bournemouth | glyn-ellis - 5/9/2012 5:10 AM Do you know the differance in weight between the k series and t series?? Fully dressed with all the bits and bobs ect yes about 60kgs, but engine is about 15 kgs lighter than a t as the flywheel is lightened and the water / pas pump has been removed But the additional weight of turbo and charge cooler should add about 30kgs Basically the idea is to be under 900kgs Also got the bottom engine mount made too Engines sitting where it should now | ||
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| Elite Veteran Posts: 697 Location: leigh | |||
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Expert Posts: 2812 Location: Bournemouth | 450bhp would be perfect but think ultimately the turbo wont give me 400bhp unless i go past 2 bar boost 400bhp/tonne will be just about right Could ultimately get 500bhp/tonne but would need to get weight below 800kgs but i like electric windows | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2029 Location: sittingbourne, kent | do you think your have it ready for 28th october (santapod ) | ||
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 10/9/2012 2:39 AM do you think your have it ready for 28th october (santapod )Yes mate that's the day I beat the fastest rover metro in the UK and daz too | ||
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Expert Posts: 2029 Location: sittingbourne, kent | djwilma - 10/9/2012 6:51 PM R100_vvc - 10/9/2012 2:39 AM do you think your have it ready for 28th october (santapod )Yes mate that's the day I beat the fastest rover metro in the UK and daz too lol Daz has some fat super squidgy slicks fitted on some 13's so should be interesting... Mine has gone on a slight diet and better gear ratio and semi slicks but probably wont be enough tbh | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2029 Location: sittingbourne, kent | Dont forget your spare drive shafts | ||
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Expert Posts: 2812 Location: Bournemouth | Thanks Sean ! Well the turbo and manifold are in its a little tight but nothing a few bits of heat shield cant help   Edited by djwilma 10/9/2012 8:58 PM | ||
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Extreme Veteran Posts: 592 Location: kent | R100_vvc - 10/9/2012 7:25 PM Dont forget your spare drive shafts and a crash helmet! will be towing mine up to pod, but am looking forward to a drag race with you and sean dont forget about that bet we made, 13.4 is the time to beat.  | ||
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Expert Posts: 2812 Location: Bournemouth | What bet | ||
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Extreme Veteran Posts: 592 Location: kent | beat the time and get your sign on fee paid | ||
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Expert Posts: 2812 Location: Bournemouth | dazz 111 - 11/9/2012 2:19 AM beat the time and get your sign on fee paid Why o why do i make these bets ! Couple of bits turned up today Gaz Gold Pro from junks thank you sir 3" 200 cell cat rated to 400bhp Vibratechnics engine mounts for k series but using the motorsport harder compound for the engine  Oil cooler is next problem the 620 oil pump doesn't have any tappings for the cooler and they are in the wrong place so looks likely to be a remote filter with cooler attached Got a couple of extra naca ducts and bought a 4 inch inline fan to circulate air when stationary or higher temps Also got a turbo blanket as it was cheap | ||
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Expert Posts: 2812 Location: Bournemouth | 3 inch down pipe was made yesterday nice tight fit but it's in  | ||
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Expert Posts: 2029 Location: sittingbourne, kent | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Ok cut the firewall today, actuator needed to go on the otherside so thought it best to cut out the panel for a bit of extra room and also ease of inspection of the turbo as it will be engine out otherwise Gearbox sits on the same mounts but about 25mm further towards the passenger wheel so the gear linkage needed a little tweak Vibratechnics mounts are in, spoke with Phil today and he is happy with the way its in. even mentioned the drivers side engine mount is used on the supras and 700lbft so should be ok (y) But, bought a new toy, its called the S-dash. I am not a fan of lots of gauges in a car, esp when on a mission as its the last thing you look at, i loved my DASH2 in the metro as it had hi-lo alarms but didnt want to change the std stack on the elise to keep the car looking std as possible. So Drew at Roverdose showed me this S-Dash made by a guy in Belgium. It plugs into the DTA (one of the reasons i bought the dta) and can show 48 channels of information. Basically everything the DTA can see if will show and it has HI-LO alarms that can be configured to rpm, temp etc So above 12.5 AFR above 6000rpm below 15 AFR below 10% throttle etc It also has shift lights built in, is a data logger with 8mb memory, can hold 8 maps downloadable in 5 secs and an easy wipe screen incase i get any more excited :wub :up    | ||
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 purple_metty Posts: 2165 Location: leicsestershire | Your one sick puppy, this is going to be nuts That dash is proberly worth more than my metro... | ||
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Expert Posts: 2812 Location: Bournemouth | redgrave66 - 18/9/2012 4:00 AM Your one sick puppy, this is going to be nuts That dash is proberly worth more than my metro... Not expensive at all that's the beauty, 200 about the same as a decent oil temp and oil pressure gauge | ||
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purple_metty Posts: 2165 Location: leicsestershire | what will you call your spare maps? Rainmode etc | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | redgrave66 - 18/9/2012 8:09 PM what will you call your spare maps? Rainmode etc I think rainmode = off | ||
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Expert Posts: 2812 Location: Bournemouth | The exhaust is in. Its 3" to after the cat then splits to twin 3" I did think about twin cats but heat and extra restriction put me off. Exit should use the std lotus tail pipes  | ||
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 Expert Posts: 4458 Location: Jelling, Denmark | that is a serious and expensive looking exhaust | ||
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Extreme Veteran Posts: 592 Location: kent | |||
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Expert Posts: 2812 Location: Bournemouth | Charge cooler and like work are now in Should have most of the small jobs finished this week the all I have to do is wiring loom and map the bloody thing get it home and respray All sounds so simple  | ||
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Expert Posts: 2812 Location: Bournemouth | ding - 3/12/2012 5:19 PM Look forward to beating this when mines finally done Yours will never be done  | ||
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Metro Mad Posts: 7653 Location: Tamworth, Staffs | Nice progress, would have thought this would be on hold for a while with more important things being taken care of, or have you managed to work your way out of doing anything | ||
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Expert Posts: 2812 Location: Bournemouth | R119GTA - 4/12/2012 3:36 AM Nice progress, would have thought this would be on hold for a while with more important things being taken care of, or have you managed to work your way out of doing anything The latter it's with a man that can, but he just had a baby so been slow. Should have all the little things done this week then home for Xmas to get sprayed | ||
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Metro Mad Posts: 7653 Location: Tamworth, Staffs | djwilma - 5/12/2012 8:26 AM but he just had a baby so been slow. bet that was painful look forward to seeing more progress plus it may make me think about doing more on mine lol | ||
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Expert Posts: 2812 Location: Bournemouth | Things have been a little slow due to baby and a job promotion but back on track  Suspension is on brakes fitted, ap 4 pots but with 308mm solid discs from a vectra not pretty but at 125 a set drilled and spigot type insert I had to try it. Braided all the pipes too Dta has lots of features one is launch and traction control which is four channel so had to mill some marks into the disks. Will also give speed to the ecu so I can trigger radiator fans and engine bay fan to come on at low speeds to counter act heat soak Loom is made and engine should be running this week   | ||
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Expert Posts: 2812 Location: Bournemouth | Right things are moving again Swirl pot is made being fed by std fuel pump then Bosch motorsport item to the injections  Cooling for the turbo  Should be running tomorrow.......sighs | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Custom dash little bigger than I wanted but should be ok Dash displays all parameters on the ecu Three buttons are launch control, wet / dry traction and on/off traction control Two potentiometers control variable boost 11psi to 29psi and variable traction control  | ||
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 Admin Posts: 1576 Location: Burnley, Lancs | |||
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Admin Posts: 1576 Location: Burnley, Lancs | |||
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 Border Crosser Posts: 3232 Location: Carmarthenshire, Wales | |||
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| OrangeManDan - 14/2/2013 11:01 PM ding - 14/2/2013 10:15 PM Why do you always talk s**t?It's true what Dan say's about you. Your a misserable fooker. Finished welding them myself today as you said you couldnt do them. Go drink a few low percent tins of larger like an alcy Calm down you fat ginger knob. He knows how to take what i've said ffs. Dont start sulking and worrying again you twat.
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Border Crosser Posts: 3232 Location: Carmarthenshire, Wales | Probably should have put it there after my comment too | ||
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Expert Posts: 2812 Location: Bournemouth | <--- Better put that for you to know i'm taking the piss! I remember having to do this all the time | ||
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Expert Posts: 2812 Location: Bournemouth | <--- Better put that for you to know i'm taking the piss! I remember having to do this all the time | ||
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Expert Posts: 2812 Location: Bournemouth | RR D-Day is tomorrow !  | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | Nice result man Timing reduced to lower boost though? You mean boost turned down to lower boost? | ||
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Expert Posts: 2812 Location: Bournemouth | munday - 23/2/2013 6:45 AM Nice result man Timing reduced to lower boost though? You mean boost turned down to lower boost? No was on actuator pressure so no modulation. Should be 11psi but creeping up to 14, knocking back ignition gave more power. | ||
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Expert Posts: 4458 Location: Jelling, Denmark | impressive result! no clutch trouble this time then? Edited by DotMatrix 24/2/2013 8:00 PM | ||
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 24/2/2013 4:00 AM impressive result! no clutch trouble this time then? Not yet, but i have the same clutch as the metro fitted This time without gearbox oil and misalignement, i hope | ||
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Expert Posts: 2812 Location: Bournemouth | Munday you were right more ignition not less, apologies Bit of a pain but the water pump to the dyno brake broke today so didnt quite manage to get it all done. Here is the curve for the first curve, timing is now correct but still needs cam timing and more boost but its a nice start. Boost is rising higher up which I think is the wastegate being to small but its not the end of the world. Still needs to rev more but its a good base.......hopefully tomorrow but 400bhp looks achievable hopefully more   | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | djwilma - 27/2/2013 10:39 PM munday - 27/2/2013 6:29 AM Definitely looks like boost is creeping at higher rpm. What boost control you using? Internal waste gate? EDIT: Just re-read (the first post), you running the 2860? My opinion...to small turbine to make the power at the rpm you want. I don't suppose you have a pre turbine exh pressure? Not a 2860 a Gtx2867 Creep is waste gate and boost control is better on higher boost. Lack of up top power is cam timing Lack of power up top is due to the 67mm turbine! Cam timing might help but it's a band aid IMO. Boost control at high boost I'd better because you're demanding a lot less flow from the waste gate! Trust the engine development engineer mate | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | djwilma - 27/2/2013 11:10 PM Not bothered about boost creep and wastegate, can always fit a external one As for the 67mm compressor, i would suggest you look at the compressor map first.....plenty of 2.0 turbos running more than 400bhp at more than 7000rpm on the 0.64 a/r turbine housing. Trust the fluid dynamics people Cams are massively retarded, i have no lift at TDC Ok, so I did some reading. The 2867 has a 58mm turbine (my bad). Looks like its designed to run high pressure ratios and still be efficient. Basically meaning you can run with a smaller turbo at higher boost to make the power. So the turbo is probably quite capable of the power you want. BTW I didn't say the compressor was too small, 67mm is enough for plenty of power. Get the boost in there then sort the cams out, even on a gash T series it should be respectable. And dont you dare call me retarded again | ||
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Expert Posts: 2812 Location: Bournemouth |  So cams were checked and inlet was 1.8mm at tdc and exhaust was the correct 0.42mm. Inlet has been corrected and it made another 40bhp. But the dip in power at 6250rpm is still there. It does recover so tomorrow we go for more. But exhaust manifold gasket is blowing so needs changing. Could be turbine housing but its got no more boost on the 11psi actuator. So do I up the turbine housing to 0.82a/r and bolt on a 14psi actuator. Or just accept it will be quick enough with 450bhp per tonne and get it on the road ! | ||
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Expert Posts: 4458 Location: Jelling, Denmark | couldn't you kind of do both? get it on the road and start using it a bit while you wonder about whether to try and go for more power. maybe you will figure out other stuff that is more important to do on the car while trying it. very nice power by the way! bet that makes one very fast "canoe" Edited by DotMatrix 28/2/2013 6:11 PM | ||
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Expert Posts: 5629 Location: Letchworth/Basildon | You already know what I think, get it out there on the road and track | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | So 382bhp and 371lbft just doesnt cut it, actually 6250rpm doesnt. C6 gearbox is just too short so need more revs, may loose a little bottom end but hoping to gain 1500rpm top end So, i made some enquiries and came up with a plan of a ported and polished head with Mechanical Lifters, uprated single springs and some billet cams. So i managed to get a head, its been ported but i only paid £200 for it, add to this the mechanical lifters and the springs (same as a k series) i purchased and all i needed was the billet cams Spoke with Grant at gb-ent and he said £800 plus VAT, Piper said 1200 so i thought long and hard and in the end have sent some cams for a re-grind to Piper 285M via Drew at roverdose. Not ideal but i havent even driven the bloody thing yet !! In fact the only elise i have driven is a 340R, to the end of friends road and back, and a S2 of Junks, where i reversed 20 yards. So the head malarky, will happen after the summer, car is on its way back as we speak from JDM Dyno in Cumbria so i can enjoy it as its nearly a year since purchase. Pics of Ported Head, David Bailey eat your heart out  Exhaust  Inlet  Oh and the seats i have are blue and material, as the leather seats were sold, so i bought this drunk off of ebay........  They have a stamp saying 2002 so assume close enough for now Plan is to get it re-sprayed and on the road within the next 4 weeks........ | ||
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Expert Posts: 2812 Location: Bournemouth | The car arrived home a day early, i was just trying to check in to a flight to Norway (which i missed), when the nice man called to say he was 30 mins away. Long story short my brother met the man and car is now at friends Lock Up awaiting being stripped and re-sprayed.......Starlight Black as per the original car Engine in, only issue is the throttle cable hits the bonnet, so may need to adjust one of them.......  Nice big Dump Valve  Ickle Bit tight for the turbo but a ahem "Chimney" style heat shield, turbo blanket and baulkhead has been given the heat shiel treatment. Should help, undertray has a massive naca duct in it underneath and engine bay has a 4" in line fan to move air around when stopped or hot...  Charge Cooler, looks like a custom fit.....however its a Fiat Seicento std radiator, which is twin pass, with a modded end tank to take the 19mm tube to the charge cooler  Rear looks fairly std, as it has the original 3" Lotus ends :cool  Vibratechnics engine mount, and a few things in where the wheel arch should go so may need a little move around :beat  Inside the car we added the AFR gauge, the centre consol can do it but easier to look at the MTX, passengers knee may hit it so will remove the wifes right leg if this happens (y)  Front Clam with triple pass Pro-Alloy rad with 2 pull radiators.....charge cooler also has fans on back side for added cooling  AP 4 pot brakes look tiny against the 308MM discs, from a Vectra re-drilled to suit Elise Hub, all under std 111S wheels :o  Little, bad video, have explained to mate never to rev and switch off the engine again......or i kill him http://www.youtube.com/watch?v=i2D818jHGfI&feature=youtu.be Sounds and footage is terrible so will get a better one later. Its has a resonance through the longer pipe, so blocking this quietens the exhaust.....just in case its too loud i can bung a bung or orifice into it | ||
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aka chris_evz Posts: 2726 Location: brynna south wales | |||
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Expert Posts: 4458 Location: Jelling, Denmark | looks like a serious set of front brakes | ||
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 28/4/2013 3:04 AM looks like a serious set of front brakes Ap 4 pots with 308mm discs Should be ok | ||
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Expert Posts: 8490 Location: Midlands | djwilma - 28/4/2013 9:16 PM DotMatrix - 28/4/2013 3:04 AM looks like a serious set of front brakes Ap 4 pots with 308mm discs Should be ok When you uprate the tyres I assume theyre on the 'to-do' list? Awesome build! | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Well things slowed to a halt, promotion at work lots of travel and so on have meant the cars been on the back burner but finally getting things done The throttle linkage needed changing as the m series inlet was fouling the rear clam, now fits underneath  Wiring is a mess so having this tidied up and the addition of a seperate fuel pump relay for the motor sport pump  But the main issue is the front clam. Bodge it and scarper painted it a lovely blue which had gone crazy. Tried to sand it off and it goes too mooch and clogs the paper as they just painted onto the original paint without sanding. Only way to remove is with a scraper which is time consuming   Hoping to have the car complete by end of june | ||
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Expert Posts: 2812 Location: Bournemouth | Well this is becoming annoying. Been so busy with work the car hasnt moved on much. So today I left early and finally did some stuff The fuels pumps have been wired in on seperate relays now, but on running it up it now has a fuel leak on the old regulator, so have to change the fuel rail grrr  But final got the rear inner arches on  And the front n/s. Am I right with the fusebox and relays ?  | ||
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Expert Posts: 2812 Location: Bournemouth | Failure.......this is the word of the day but in the grand scheme of things, and after some soul searching and being told not to be grumpy "its only a car" i have come to terms with the MOT failure today ! It didnt fail on much, i couldnt find the drivers side mirror, the aim on one of the lights is low but worst of all the steering rack is buggered. So basically the car looks like this now   It needs to be sprayed but my insurance company are threatening to cancel the policy so it had to be done this week. Here it is on the MOT Bay at K-tec racing, passed the emissions no problems, but it ran out of electricity and has sprung an oil leak.....so off with the rear clam again !  But before all that went Pete Tong we took this video, not be driving as Scott cant use a camera its 20 seconds of your life you wont get back, but even i am thinking this doesnt exist sometimes ! [youtube]www.youtube.com/watch?v=ohsScfjDDK4&feature=youtube_gdata_player[/youtube] | ||
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Expert Posts: 4458 Location: Jelling, Denmark | annoying that it failed, but I guess you were maybe kind of expecting this. minor things to fail on anyway but nice that you have gotten so long so to be going to MOT's a bit of paint would make it look much better | ||
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Expert Posts: 2812 Location: Bournemouth | Well i know the reason the rack felt ok but was horrible to drive / failed the mot The casing was cracked on the passenger side close to the pinion..... Luckily i ordered a new rack from the ever quick elise parts, went for the quick rack as it sounded cool so its fitted and feels so much better Awaiting the plinth for the drivers mirror, apparently lotus only process orders on Wednesday so i have to wait till next week.....if anyone has a spare drivers side please let me know otherwise i will bodge something on for Friday as need to get it MOT'd or the insurance will be cancelled    | ||
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Expert Posts: 5629 Location: Letchworth/Basildon | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Car is now road legal ! Now to sort out lack of electricity and oil leak......exhaust manifold maybe leaking as well ffs Then get it sprayed, then uprated links and geo Then actually drive it !!!  | ||
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Transport Guru MP Moderator Posts: 4947 Location: Bromley, Kent | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Quick update, the alternator belt was on and the connections tight so assumed it was the alternator gone / fubarred Luckily i have an inspection hatch behind the drivers seat so i had a quick look and managed to get the alternator out, little worried it has no heat shield so will place one on it when back on. Took it to local alternator checking place (technical term of course) and they span it up and deemed it a working alternator !!!! A little confused they suggested i could of dropped it / rolled about the car and the bushes maybe connecting. I hope so, so i asked them to refurb as i have no idea what alternator it is.  Once the alternator was off i went in search of the oil leak, so off came the rear clam, and found the exhaust manifold was leaking This is the second one to go so the flange (he he) cant be straight so it will have to come off and be skimmed.......I did tweak the bolts and it has made it better. Oil leak though, seems to be the cam carrier so will have to take off the rocker cover and tweak the bolts. I have a ported and polished head with some wilder cams to go in so may just do it all at the same time but this will be after the Geo and Spray job.....  Bought some upgraded Toe links from Elise Parts too, thought as the geo will be done in the next few weeks i might as well upgrade them.....plus the plan is to get some ZZR's and do some track days | ||
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Expert Posts: 2812 Location: Bournemouth | So its not the altenator, although it did have a leaking diode, put it on and 11.8Vs So we did the unthinkable and checked the main alternator fuse, and as per the pic below, it was blown. So we change the fuse and bingo, 12.8v's, then bang fuse popped again. Looks like i have a short circuit and as i hate electronics i have to wait for a man to do it.......arrgghhh Anyhow the rear clam is being sanded down, primered and should be sprayed by the end of next week.......which i have been saying for about a year so fingers crossed  | ||
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 Forum Admin & Insurance Guru Project Pride Posts: 5690 Location: Durham - North East UK | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 8490 Location: Midlands | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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| Expert Posts: 4262 Location: Tebworth | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 8490 Location: Midlands | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Forum Admin & Insurance Guru Project Pride Posts: 5690 Location: Durham - North East UK | |||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | cerbera - 4/8/2013 10:27 PM djwilma - 5/8/2013 1:11 AM Got an 80 and 100 just in case Just whack a screwdriver bit in, job sorted then it will never blow! warning ! warning ! warning ! northern mechanical advice is being dispensed, act on it at your own risk no wonder we didnt defeat the scottish | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Finally things have started to move on the body work, been a nightmare as friend who is spraying (and has been paid to do it, silly school boy error) has been off work for a while with various problems. But its now promised to be done in the next few days I have a few electrical issues to sort too, central locking has stopped working, battery is now discharging when ignition is off and also a few mechanical ones Think as the car is being stop started a lot, the plugs have fouled up as its running on 3 cylinders, and the exhaust manifold is leaking for the second time so i think it was bent when welded and needs to come off. Luckily i have the mechanical cams and ported head to go on so will have to do that sooner than expected. Just want it finished now so i can enjoy the british summer........doh      | ||
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| Master Parts Seller Posts: 2380 Location: Andover Hampshire | |||
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Expert Posts: 2812 Location: Bournemouth | Put some base coats on the clams, rear looks lovely in matt colour but the front reacted badly to the paint, which is why it was crazy paved before. Car will be painted original Starlight Black bit of a bugger but at least it coming on now  | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | djwilma - 21/9/2013 10:14 AM Put some base coats on the clams, rear looks lovely in matt colour but the front reacted badly to the paint, which is why it was crazy paved before. Car will be painted original Starlight Black bit of a bugger but at least it coming on now You told me white you gaylord ! | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Woo hoo starting to get somewhere paint is on clams....car will be done next week Was tempted by the matt colour but its shiney with laquer bad news is I now have an oil leak from the cam cover arrrgghh      | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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Expert Posts: 2812 Location: Bournemouth | Got the clams on the car today ready for flatting and polish Still have the doors, roof and inspection pods to spray shouldnt be long (sure i have said this before)    | ||
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 Veteran Posts: 310 Location: nr Evesham Worcs | Love it, its looking awesome now.... Major dose of car envy, i will have a audi 1.8t powered one, one day | ||
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Expert Posts: 2812 Location: Bournemouth | Ed Norton - 28/9/2013 2:08 AM Love it, its looking awesome now.... Major dose of car envy, i will have a audi 1.8t powered one, one day not easy to do at all, engine and box sit much lower and wiring is a nightmare Plus the conversions cost 10k to do And worst still they are very heavy but a good one sells for 30k ! | ||
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Expert Posts: 2812 Location: Bournemouth | 240R spoiler turned up today many thanks Alex hopefully have it sprayed tomorrow   | ||
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Forum Admin & Insurance Guru Project Pride Posts: 5690 Location: Durham - North East UK | |||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | cerbera - 6/10/2013 3:14 PM It's really starting to take shape now, looks great! but its a gay hairdressers car ! | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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Expert Posts: 2812 Location: Bournemouth | Well the good news is......... Its on my drive, tucked up nicely in its new pyjamas Drove if home and it's geo is all over the place, the brembos rattle, the shocks are set too hard, suspension is too low, oil leak drops onto exhaust manifold which is leaking.........body work needs some flatting polishing and a few chips from fitting. but its on my drive and third gear with foot to floor is a giggle exhaust sounds lovely too Photo when it was light....its all together now  | ||
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Extreme Veteran Posts: 592 Location: kent | Looking goood | ||
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| When do i get a go? | ||
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Expert Posts: 2812 Location: Bournemouth | ding - 7/10/2013 8:18 PM When do i get a go? When I get my wheels back | ||
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Expert Posts: 8490 Location: Midlands | Good work, really is quite a transformation! Can i ask what you paid for the written off car? I still fancy an S2 | ||
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Expert Posts: 2812 Location: Bournemouth | Adi will pm you, issue is they are going up in value at the moment For cheap thrills I would go s1 and std k turbo sean spec A big smile is an understatement ... Nearly finished it off today. Still needs some flatting and polishing and grills adding. I am missing the front undertray so cant fit the splitter which is a shame. 111S Stickers to go on to but just so excited I couldnt help but put photos up its booked in with Sportomotive on thursday for a Geo, going to go for 340r setup at 120mm front so I can go over speed bumps had a little play on the way home and a nice man and his Pillion on a motorbike Aprillia Rv4 assisted with the how quick is it test......on low 11psi setting it was close thing.....so I would say its quick enough     | ||
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| djwilma - 8/10/2013 12:24 PM ding - 7/10/2013 8:18 PMWhen do i get a go? When I get my wheels backThat's a never then | ||
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Veteran Posts: 310 Location: nr Evesham Worcs | Looking awesome | ||
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Expert Posts: 2812 Location: Bournemouth | Thanks Ed ding - 8/10/2013 3:17 AM djwilma - 8/10/2013 12:24 PM ding - 7/10/2013 8:18 PMWhen do i get a go? When I get my wheels backThat's a never then Thieving valleys scum, your missus was right about you Issue of the day today is Car has a new battery and a re-furbed altenator and was charging fine yesterday....14.2 V on ECU readout First problem i had was the Bosch Motorsport Pump draw too big an AMP for the MFR as i had the std pump and bosch pump running on s ame relay......which frazzled So i had a second 30a relay installed and since then the car has been popping main fuses, 60A first then 80A and now with a 100A fuse in there i was driving home I noticed the volt meter saying 17V at one stage before the 60A fuse popped and the car stopped charging Car also drains the battery when stationary...takes about 4 hours to kill it I managed to get it home but upon changing the fuse the battery is not charging. The altenator light is off, goes on when i remove the main fuse. | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | djwilma - 7/10/2013 10:51 PM Well the good news is......... Its on my drive, tucked up nicely in its new pyjamas Drove if home and it's geo is all over the place, the brembos rattle, the shocks are set too hard, suspension is too low, oil leak drops onto exhaust manifold which is leaking.........body work needs some flatting polishing and a few chips from fitting. but its on my drive and third gear with foot to floor is a giggle exhaust sounds lovely too Photo when it was light....its all together now SSCCCHHHWWWIIINNNGGGG very nice !!!!! | ||
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Expert Posts: 2812 Location: Bournemouth | Woo hoo it has electricity ! Dont know for how long but it managed to get to the local track for a quick blast up the straight, did a 3rd and 4th gear on low 11psi boost You can hear the exhaust manifold blowing and its a little laggy, also ECU light is linked up to the DTA and comes on when its time to shift Edited by djwilma 24/10/2013 2:01 PM | ||
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Extreme Veteran Posts: 592 Location: kent | |||
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Expert Posts: 2812 Location: Bournemouth | dazz 111 - 23/10/2013 10:17 PM Looks good that, so its basically all done now then? yes apart from full suspension geometry, flat and polish, few grills, ported head 285 cams and mech lifters, exhaust manifold is leaking, front splitter and a bit of touch up paint (scotts fault) Should be good for Summer | ||
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Extreme Veteran Posts: 592 Location: kent | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Extreme Veteran Posts: 592 Location: kent | That 12.8 was at 19psi, its on 23psi now with r888 so hopefully should be getting low 12's Oh and a new itg cold air filter Edited by dazz 111 24/10/2013 5:14 PM | ||
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| Went to see Dylan today and he asked me to show what he's been up to as he hasn't got time. I'm not a fan myself, but he seems to think it's good..
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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| Master Parts Seller Posts: 2380 Location: Andover Hampshire | djwilma - 24/10/2013 1:48 PM Woo hoo it has electricity ! Dont know for how long but it managed to get to the local track for a quick blast up the straight, did a 3rd and 4th gear on low 11psi boost You can hear the exhaust manifold blowing and its a little laggy, also ECU light is linked up to the DTA and comes on when its time to shift looks nice and quick, if thats real time 43 to 123 in just under 12 secs | ||
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Expert Posts: 2812 Location: Bournemouth | ding - 12/11/2013 2:31 AM Went to see Dylan today and he asked me to show what he's been up to as he hasn't got time. I'm not a fan myself, but he seems to think it's good..
Its looking good hey Ding.....just needs those wheels of mine you have to set it off Tony, that was real time and on low boost Well after the Ported Head i purchase was a dud, i decided to go all gung ho and get a new head ported by Jason Hellier of Hellier Performance as he is 20 mins from my house and i have heard good things about him. He is also good friends with Rog from Sabre heads and i would like to thank rog for his help. Anyway, i asked for Jason to Flow Test the new head, the old cracked one (supposedly a GBE head, but its not) and the std head to see what flows i would get. The cams i have are 260 degree 285M Piper re-grinds with just under 10mm lift so figures at 400 thou are roughly this. The std head flows ok, the cracked head did well on the inlet but basically bugger all improvement on the exhaust even though massive amount of metal was removed. Luckily Jason spotted this and his head flows approx 20% more than the std head on the inlet and exhaust so i cant complain. All test were done on the Janspeed Flow tester in CFM Cams were set up and measured, took a day apparently, single piper springs (157lb @ 10mm vs 128lb std springs) with modified std caps for a 7500rpm limit. But i now have a solid tested head so i hope this helps with the lack of top end revs. Car is with JDM Dyno in Cumbria who will strip the head and re-dyno with a few other minor mods            | ||
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| Master Parts Seller Posts: 2380 Location: Andover Hampshire | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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| Master Parts Seller Posts: 2380 Location: Andover Hampshire | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 5629 Location: Letchworth/Basildon | djwilma - 19/11/2013 8:46 PM Well the head is off and new head going on tomorrow Looks like the old head had been ported slightly Exhaust manifold was warped, its been skimmed and ready to go back on Oil leak was not what I expected. The cam carrier was leaking, but small amounts. Main problem was it was coming out the dipstick straight onto the exhaust manifold....so will add a couple of breathers. Should be on the rollers on Friday for 400bhp........ Oil out of the dipstick.... Oh dear  | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth |  This is what happened today.....low boost is 11psi so spot the problem Looks like the std garrett wastegate is too small and now I am getting more flow through the head it just cant cope so backed out at 6000rpm. Still 360bhp but at 19psi so really have no control ovet boost So ordered an external wastegate and will get this fitted next week.just a shame internal wastegate doesnt flow enough but external will control better 44mm tial on order Worse is the fact the tyres wont grip on the dyno, then I saw this plot and realised why  | ||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | djwilma - 25/11/2013 10:31 PM p319 hok - 25/11/2013 6:25 AM thats more torque than my 'biza had at 3000rpm - WOW ! bet thats a handfull Not quite, its at 3709rpm, dyno miscalculates with wheelspin or clutch slip...... either way please dont mention Ibiza's on my thread...... your jyst pissy because you loved it | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
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Expert Posts: 2812 Location: Bournemouth | Wastegate is welded in Just hope it all fits, bit "compact" but should be ok  | ||
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Expert Posts: 2812 Location: Bournemouth | View from underneath  | ||
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Expert Posts: 2812 Location: Bournemouth | Been a bit of a struggle to get things fitted External wastegate needed to be plumbed into the water system as it was literally surrounded by exhaust Anyway set point of 1 bar and it did the below, with a nice flat curve  Then set point of 1.63 bar and progressive boost control, it did the below, squiggle is wheel spin  On monday we will take the cat off and run it at 1.8 bar for a giggle but will run it at 0.9 bar on the road with the cat and just de cat for the track as its all v banded in So all in all quite happy and at 850kgs its 470bhp/tonne | ||
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Expert Posts: 2029 Location: sittingbourne, kent | You should be able to beat a metro now must feel good with that large amount of torque | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 18/1/2014 12:30 AM You should be able to beat a metro now must feel good with that large amount of torqueI should of beaten you on the two previous occasions so it wouldnt surprise me to ne seeing the rear of your metro at santa pod Torque is lovely, like lovely as long as its above 2500rpm it just goes.....quickly But its in cumbria so havent driven it for about 6 weeks......be a nice drive home on sunday Edited by djwilma 18/1/2014 4:52 PM | ||
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Expert Posts: 2812 Location: Bournemouth | Well just home, wife kicked me out of bed as cant sleep so might as well do something useful So drive back from JDM Dyno was 365 miles and car drank approx 45 litres of 95 ron petrol which i calculate at roughly 37mpg....manly motorway driving with a few ahem spurts. Happy with that Few issues though 1. Dipped Beam Headlights are terrible, I heard rumours they were pants but my gawd 2. Windscreen wiper stops where it likes on inter wipe, and stops completely on high speed 3. AP racing pads rattle, i understand this is normal 4. Fifth Gear is pain to select 5. I have a Kestrel Kevlar Clutch, fairly new and they are supplied raw and need bedding so clutch is / has slipped 6. Could get the clutch to hold on the Dyno, we thought it was wheel spin but i had clutch slip on way home 7. Its loud in the cabin, i thought 111S' were quieter lol All in all i am very happy with the car, 80mph is 18% TPS 50mph is 6% probably needs a little more mapping below 2500rpm but for now its fine. Manage 6 hours, ears arent ringing but blown a speaker. Had to fit an aerocatch for the boot though, not sure if it looks right right but its a fix i had to do AIT temps at motorway speed sat nicely at 13C, highest on Dyno after third quick run was 45C And best bit, she is quick, very quick only had it on low boost 0.9 bar but its mental and i had no traction issues so either i am amazing, the diff is working or the traction control is doing its job. Must be the first one De-cat spooled a little quicker, and made 30bhp more at 1 bar boost 356bhp vs 321 so in theory its good for 450bhp (my story and sticking to it in the pub). video you can hear the slippage http://www.youtube.com/watch?v=LkjAxMpnSOg Dyno printout of run  De cat Pipe V banded in  Larger Naca Ducts Fitted to undertray  JDM Dynos own built Mk1 escort, 2.9 V6 Cosworth (from the Scorpio no less) 350bhp 1/4 mile of 12.4  | ||
| munday |
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Expert Posts: 5629 Location: Letchworth/Basildon | When will you learn and buy a proper clutch  At least the rest of the car is working well | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | munday - 20/2/2014 3:26 PM When will you learn and buy a proper clutch At least the rest of the car is working well Lol cos if it doesnt work its a whole new world and 7 1/4 " clutch new flywheel and modded bellhousing | ||
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Expert Posts: 5629 Location: Letchworth/Basildon | djwilma - 21/2/2014 7:32 AM munday - 20/2/2014 3:26 PM When will you learn and buy a proper clutch At least the rest of the car is working well Lol cos if it doesnt work its a whole new world and 7 1/4 " clutch new flywheel and modded bellhousing Dude, Helix or AP would have something off the shelf to meet your specs | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| munday |
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Expert Posts: 5629 Location: Letchworth/Basildon | djwilma - 21/2/2014 10:33 AM You would think so wouldnt you AP dont Helix do but 325lbft, just, but pressure plate is heavy and so on The Kestrel better start gripping thats all i will say Hope so too man | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| Paul r |
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| Extreme Veteran Posts: 539 Location: Swindon, Wilts | Build an rts clutch with a good pressure plates | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | looks quick in that video | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 22/2/2014 11:35 PM looks quick in that video Silly quick......i know its my car and i know i am biased but my gawd its quick | ||
| Cake_Destroyer |
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | djwilma - 23/2/2014 11:31 AM The worst video in the world, decided to go for a quick run last night to grab a few beers and went the long way Camera angle is wrong, its dark and terrble editing (give it a few seconds) Std 225 45 17 Kumho KU31 tyres (old), damp road so not too upset with little wheelspin http://www.youtube.com/watch?v=9YAiWeLbdHg&list=UUE3ZxXN2VNhtCxS-TGkPpCA&feature=share Bypass ? Looks honkingly fast, extra kudos for a southern wuss | ||
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Expert Posts: 2812 Location: Bournemouth | Tom, sorta Few more teething problems it blew the engine fuse again and looks like a small oil leak.....again.... But I did get fatty weighed, I'd like to say I was in the car but I wasnt. Suppose adding 30kgs isnt the end of the world but was hoping for 850kgs but evo list the 111S S2 as 860kgs but kinda hoped the 804kgs for the s2 was closer    | ||
| R100_vvc |
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Expert Posts: 2029 Location: sittingbourne, kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 24/2/2014 4:32 AM That's not bad at all, I was expecting more. I think my metro is probably 900kg+ with all the extras on it now Weighbridge or it didnt happen Just have to fix the oil leak and i will finally, after 3 years, be able to beat your metro at Santa Pod (hopefully if cheeky scott drives) | ||
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Expert Posts: 2029 Location: sittingbourne, kent | djwilma - 24/2/2014 8:47 PM R100_vvc - 24/2/2014 4:32 AM That's not bad at all, I was expecting more. I think my metro is probably 900kg+ with all the extras on it now Weighbridge or it didnt happen Just have to fix the oil leak and i will finally, after 3 years, be able to beat your metro at Santa Pod (hopefully if cheeky scott drives) Im just going by the Haynes manual weight of a standard metro gti 855kg ish? plus the extra weight of turbo/manifold, heavy stainless exhaust, charge cooler system...list goes on. But I aint worried I will still place a bet to win Only if you don't use extra gay things like launch control | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 24/2/2014 5:06 AM Only if you don't use extra gay things like launch control You know me too well | ||
| R100_vvc |
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Expert Posts: 2029 Location: sittingbourne, kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | R100_vvc - 24/2/2014 5:16 AM last time I was at pod, I done a 13.4 time again but had full interior and a passenger but then gearbox cracked literally so didn't run on my own. With that compared to 13.4 with you last time which was stripped out 2 seats and on my own. 12.99 is my next target £20 you wont do sub 13s (seemed to have worked both times before so there is method in my madness Right had a friend over to finish off a little of the body work, like the roof And though i would see what the oil leak was, took the inspection panel off the engine bay (a handy piece of kit to have) Saw the newly installed waste gate  Then noticed oil below the turbo and not above so poked a few pipes, noticed the return pipe was loose but no oil above it So took it off and hey presto......oops   Happy its a simple pipe so off to see what i can do to get a heat resistance one Anyway even though the engine wont keep the oil in it and the battery doesnt store electricity....its all about looking good ! (apart from the rear wheel and no centre cap)  | ||
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Expert Posts: 2812 Location: Bournemouth | I went to pirtek and the spotty 18 year old with the 600bhp 4wd starlet says this will work, those guys know everything   | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Took the car back to the ever helpful Sportomotive I wasnt happy with the Gear Change 5th was a bugger to get, so its now adjusted and much much better Was worried the brakes werent "hard" enough so had them re-bleed them and the clutch pedal felt soggy so had them change the fluid (it came out black) But main reason was to re-check the GEO which we managed to do to 340R specs but 125mm front  The steering arms were removed, luckily as they found this.....must of been the original bolt from the accident.....all changed to a new one  | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| munday |
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Expert Posts: 5629 Location: Letchworth/Basildon | DotMatrix - 5/3/2014 7:38 AM what is a GEO? I think he means Geometry | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | munday - 5/3/2014 9:09 AM DotMatrix - 5/3/2014 7:38 AM what is a GEO? I think he means Geometry aaaah. that makes sense thanks | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Arrgghhh on way to skydiving lovely 65 mile cross country blast....tweaked the shocks last night so was loving the drive.. But first thing reversing out the drive and drove into neighbours car as an idiot The the innovate lambda sensor just stopped working so chucking in fuel, common I am told Then 30mph through a village heard a thud, rear view was a pot hole and car went light at the rear. Got the tyre weld out, just came out two big holes ffs So car is parked up, and couldn't find wheel nut adaptor to undo wheels and will get her recovered once I have finished jumping....if I survive    | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Works mental so not had much time on my hands but purchased these, probably the most extravagant thing i have ever bought Carbon Fibre side scoops but they look good even if stevie wonder fitted the driver side one   AFR gauge is back quick work from Grant at http://www.gb-ent.co.uk as usual and all back up and running  Got to drive the car yesterday, shame it rained but at least its done some miles again 140 miles on a tank of 33 litres (20mpg which isnt too bad as most has been point and squirt). She is quick but has a little bump steer problems, 70mph on slight RH turn and the front was moving....assume dampers so will tweak these Exhaust is blowing though suspected down pipe so will have to check it out on the weekend, its never ending But, main fuse blew again. And this time i know why, it was loose in the engine bay and was earthing on the block. So its been wrapped and stuck to the clam shell.....so shouldnt happen again  time for a track day soon though | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | had enough of work so had a lazy day at home, and got a surprise when i went to open the drivers door this morning before my sea swim  Looks like the grill has come loose, broken the cross member and ripped out the self tapper at the top....then snapped off at the rear lug....so if anyone has a spare RH side CF side pod let me know FFS I was doing some high speed testing, on a private road, and didnt hear or notice it but full throttle (little clutch slip) and 6000rpm car was still pulling Looked at the exhaust and the turbo to downpipe had two bolts in it, school boy error but looks like the bolts are a few mm too long so they went tight but were holding. Have ordered some new studs and nuts so will try and get it finished. Eased off the shocks on the front and it rides a lot better with no bouncing Also played with the traction control and launch, now that was fun 20% slip 3500rpm a little sideways and hit the rev limiter in first a heart beat later. Cant wait to get some sticky rubber and get on a 1.4 mile | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Thanks guys Well insurance is due in 2 weeks, been a whole year on the road and only 786 miles......not enough But car has been with a friend to have the clam repaired, and stickers added (thanks BobvanM), the rear diffuser painted plus a polish. Have a little paint reaction on the drivers side under the pod so will get that done soon.....  Also got my 1275GT out of storage and on the drive so will be fitting a turbo k with 200bhp to it soon....i hope Anyway went looking for the exhaust leak, looked at the turbo to down pipe and very strange but all the bolts were too long for the threads. Good 5 mm and only being held in with one tight one. Replaced all the studs with proper high temp items and proper nuts. Lowest one was a bugger 1/8 turn each time.....  Started the car up and exhaust blow was still there, hand in and found the turbo to manifold only had two bolts in on the right hand side......ran out of the proper nuts but will get some tomorrow and take it out   Was hoping to get to Castle Coombe on the 22nd April with LOT | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| Cake_Destroyer |
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Have had Man Flu and a funeral this week so not had much chance, but managed to wire the Lambda Sensor in properly, but have a loose connect on the 0-5v feed to the DTA so need to check this.  Also the fan knob fell off when i put my foot down, then rattled around so had to stop  Then took it out for a spin today, still awaiting on the Clutch to grip it is getting better but and got the camera on forward facing. The sound for some reason is very quiet to need to re-check this too Edited by djwilma 27/4/2014 8:14 PM | ||
| AdrianSi |
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Expert Posts: 8490 Location: Midlands | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | What a lovely weekend perfect for roof down motoring, especially on my route to Swindon Sunday morning at 7am lovely country roads quiet traffic and even better the clutch has started allowing full throttle in 3rd and 4th So imagine my mood when 3/4s of the way and full throttle blast and rattle, then oil smell Drove at 2500rpm in fifth and the rattle started to get worse. Then it wouldnt tick over ! Managed to nurse it to work and let it cool, started again and it rattled, sounds like the big ends have given up. No idea why engine seems to have oil pressure 60psi is showing, however it doesnt change with Revs (assumed dodgy sender) So it spent the night on the back of a truck, again !  Worryingly i am expecting the worse and googling 2.2 t series...........hmmm | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| dazz 111 |
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Extreme Veteran Posts: 592 Location: kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| dazz 111 |
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Extreme Veteran Posts: 592 Location: kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 14/5/2014 8:53 PM couldn't you just have the big-end of the conrods honed to the correct size so the bearings don't spin? Yes but rule no 1 Modify dont repair | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | djwilma - 15/5/2014 2:39 PM DotMatrix - 14/5/2014 8:53 PM couldn't you just have the big-end of the conrods honed to the correct size so the bearings don't spin? Yes but rule no 1 Modify dont repair Sure Its more fun to build a new One but it Will probably be a lot cheaper to repair plus it developed power nicely | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Well i collect the engine on Thursday its a newly built 2068cc T series spec is as follows Engine/Box -2067cc forged using aged block, bored with torque plate -Block decked by several mm -Ceramic coated Arias Forged pistons with Moly side skirts -Pauter custom rods (changed rod ratio) rated at 250hp per rod -ARP Mains, big end and head studs -Knife edged and balanced crank, fine balanced to 10k rpm -Alloy sump -Extra breather on front of block -Wire ring grooves, stainless wire rings -Copper headgasket with custom oil sealing -New head casting taken and ported to the highest level by Sabre Heads, Roger this is Grants old engine -Oversized valves (Stainless steel one piece) -Double valve springs with custom caps -Custom race grind cams -Special cam belt (kevlar extra wide) with modified lower pulleys to suit -Vernier pulleys -Set up with 36-1 pulley and crank sensor for better accuracy on aftermarket ECU (may not fit in my engine bay tbc) -4.5kg Billet flywheel -AP Twin place clutch with custom bearing carrier (may use my setup though) -PG1 220 box ratios, built with new bearings, syncros and type B Torsen. Shimmed correctly have a W4 box so may change the final drive and get a K4 or C6 -Cut down custom engine loom, losing all uneeded wires -LS7 coils and custom leads with custom bracket - Daihatsu Charade altenator under inlet (std is under exhaust but my charge cooler is in the way)     | ||
| Cake_Destroyer |
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| formerly p319 hok Posts: 1965 Location: Under a car somewhere | |||
| Metromartin |
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MP Admin Posts: 17870 Location: Gloucester | Just watched the videos, absolutely love this car! sounds like my 620ti but image of my elise!! PS if you're in swindow or chippenham way again i'd love to drive down for a passenger ride in this Drove to Reading along the m4 with the roof down 2 weeks ago. | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Ok, so i have done some silly things in my life. Jumped out of a plane naked, woke up on a dance floor dressed in a sumo suit whilst the cleaner was cleaning around me etc etc However i have never been so embarressed as when i just got the call about my engine, seems a distinct lack of oil was the reason for the failure. It had a mere 1lt of oil in the sump, which would explain the "knocking noise" from the engine. Worst still is that the Turbo is pretty much seized solid and as its a roller bearing turbo and looks to be junk ! So a very expensive mistake, simply not checking the oil after an oil leak (return pipe from turbo) and a faulty oil pressure sensor and oil switch (Light on stack doesnt work and ecu display was set to the wrong oil pressure)...... [Censored] shit [Censored] [Censored] Anyway the good news is the new engine should be fitted in the next day or so then a replacement turbo needs to be sourced and fitted. I have bought A new clutch, helix rated to 425lbft, its a 6 paddle so i hope its more than digital A custom Inlet with bigger inlet tracks, 660cc injectors still though (may or may not fit) Placed an order for a 60litre pro alloy fuel tank New pressure switch for oil Then we can wind the bloody thing up and break the 450bhp barrier, i can sleep a happy man as long as the wife doesnt find the receipts I have thoughts of a bigger turbo, EFR Twin scroll but the injectors will need replacing and quite frankly 320bhp was more than the roads needed.........must resist Well the engine is now apart, the pistons and the head are undamaged The turbo is stiff, with no play, so its been shipped to Turbo Dynamics to see if they can repair and upgrade to ceramic bearings Rods have taken the brunt of the lack of oil, NO 2 has spun so the rods are basically junk    Clutch is in its a Helix 2.5 from Grant at GBE, hoping it will cope with the 450lbft torque and wont be too digital  Results on the Turbo are in, and its all good in the hood. Basically needed new bearings and a slight fettle and definite lack of oil issue. Lovely Service from Turbo Dynamics, they even installed their motorsport spec when they re-furbed it. I have no idea why i said yes but the word "motorsport" sounded good. Its basically ceramic bearings which needed replacing anyway. They collected the turbo stripped inspected and had it back within the week and less than half price of a new turbo. Engines back in and partly plumbed in Just going to add a smallish intercooler in the side pod to assist the charge cooler, looking at the data log its highest ever temp was 48C but its never been on track so thought we'd pop one in with a little more ducting as well for cold air. Hopefully be back in action next week.......finally Edited by djwilma 29/8/2014 12:45 PM | ||
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Expert Posts: 2812 Location: Bournemouth | Well I finally got time to collect the car, bit of an epic trip Bournemouth to Carlisle and back in a day about 760miles in total Good news was it gave me time to run the new 2.1 engine in. Was very tight when i pick it up and with wet roads it felt, well horrible. Looks good too. Need to add some heat shield to some pipework but will get this done.  Good news was that the car loosened up on the journey back, it now has a 60litre Pro Alloy tank fitted (although it only took 52 litres, petrol poured out the filler so knew it was full) and it nearly made it back on the one tank ! Engine now revs to 7760rpm according to the log so i need to re-set the limiter to 7500rpm Clutch now holds and although a low pedal it grips well, gear linkage needs some adjustment though Engine now feels lovely, had a little play with a V10 R8 on his way back from the EVO triangle, on low boost, and it was neck and neck, managed to pull up along side in a traffic jam and the driver was a little shocked....as was i..... His comment was this is silly quick and you caught me up. Did mention i had another 120bhp and he just shook his head Curves arent great to be honest, car has too much wheel spin when turning the boost up. And fueling boost etc werent finalised so these are not adjusted 1.34 Bar boost was 386 @ 6200 rpm  1.45 Bar was 412bhp but wheels were a spinning So will when i get a chance i will get some in car footage and drive by's   | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 19/10/2014 6:41 AM isn't that the same dyno result you put up twice? other than your air/fuel graph which I think looks to have slope I didn't think it should the other lines looks good I think? Was two identical curves, sorry so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin AFR ratio wasnt final on the runs so dont worry too much about them Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log  Edited by djwilma 23/10/2014 9:31 AM | ||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Been away for a few weeks so took the car for a spin today in the rain so good time to play about with the traction control. DTA has a a wet / dry setting. Dry is limited to 10% slip, but i can adjust this from the car and this allows the car to slide about to about 10 degrees by cutting up to 75% ignition. Wet is Zero slip etc Wound the boost up to 1.7 bar, 3rd gear and 60mph and put my foot down. Car accelerated hit the maxboost and the ECU cut all the power to the engine Same at 0.7 bar and she just accelerated, albeit slightly slower than in the dry Then i noticed the oil temp, its fitted to the cold side of the water and as i have the EWP it doesnt have a thermostat and was showing 12C  So got home and turned the engine off waited 5 mins, car has a turbo timer that circulates water and turns an engine bay fan on, and the gauge shows this  I think the oil temp sensor is on the cold return so will relocate it to the sump, and if its is running cold will add a thermostat. Put the hard top on and took the worst photo ever  | ||
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Expert Posts: 4458 Location: Jelling, Denmark | pretty cold oil you have there | ||
| munday |
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Expert Posts: 5629 Location: Letchworth/Basildon | There is no way the oil is being cooled down to 12 degrees C through the oil cooler. I would say either the sensor itself or the wiring to it I know not many people comment here but im always reading it and turning a little bit green | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Munday the sensor is out of the flow and not reading correctly I will swap it with the pressure sensor End of year at work is manic so had no real time, even managed to turn 40 but still look 28 so all is good Got to the bottom of the alternator belt the lower bracket failed Have re- welded it and will take it to a friends garage in the new year for a proper go as the rear of the alternator isn't braced so will add a bracket in as it flexes  Also got some quali session used ZZRs from Andy at Maidstone Sports Cars was too good a deal to say no and have a spare set of wheels so will try and get a track day organised  | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Having a busy time at work so the failed alternator bracket / belt has taken for ever However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket   Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking  | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | I like that you have painted the engine green like old mini engines regarding your cooling holes, couldn't you just remove the three grey plastic "grooves" in each side right next to the holes you made? | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Firstly apologies to the nice fellow that spotted my Elise at Tech1 in Poole and asked for an update. Work and family have meant no time for me to spend on the elise. Finally found the electrical problem the cobra siren had gone open circuit and caused all.sorts of weird problems New alternator is fitted and cars running well Put a new oil temp.sensor into the sump and temps sit nicely at 85c but hit 112c on a spirited run so need to keep an eye. Dash only logs highest data so may just of been a spike.  Was of course on a track at the time Also had a little mod done to the front as only ever got hot air through the vents and as long as I am.moving it's worked well.    | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Couldnt see diddly out of the dipped head lights so swapped for Philips 55w 150+% bulbs and had the very very scratched headlights cleaned. Found lots of primer / paint on the lenses too I can now almost see when driving.........    | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2812 Location: Bournemouth | Have been getting terrible mpg 60 litres and 150 miles which I just put down to the right foot giggles But decided to re calibrate the AFR gauge and it's made a massive difference, thought the fuel gauge was faulty at one point but it's now moving Odometer was zero'd so fairly happy if thats the end result  Next post I am sure will be a i ran out of fuel one Next issue is body work, I have the same problem on both sides a horizontal cracking on the lower section Any idea why     | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | It seems the infamous blowing of the main fuse is back Looked at the log and it spiked at 16.9Vs Whats more annoying its its not part of the loom that i have touched, its still the standard elise wiring Popped a new fuse in and meter reads 11.1volts, but the red light is not on. So, the alternator was stripped and inspected No heat damage, no signs of over speeding and the regulator and diode packs are blown. They are connected so.....only a few things that blow these. Heat, overspeeding, bad earth and bad positive So will run an earth from the chassis to the alternator case and see what happens. Decided to tidy some things up, Randy mentioned it once and it's been annoying ever since. The before photo  Added in an Ali plate below the charge cooler so most of the air passes through  I have never had an issue with the Rad always sat high and had a lot of gaps, and the chargecooler rad had gaps behind it so thought about moving thing around.  Reason for this was std fans were installed for the charge cooler, but these restricted flow to the main rad and did little when stationary. So removed these and reset the main rad lower  Next was the charge cooler pump, it used to fly free but added a bracket to the pump. Orientation is terrible.but best we could do  Next was the windscreen wiper, purchased a new motor and fitted it. Same as before, intermittant is 2/3rds of the screen and stops wherever it wants and high speed does nothing. Assume this is the relay so will change that  | ||
| R100_vvc |
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Expert Posts: 2029 Location: sittingbourne, kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
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Expert Posts: 2029 Location: sittingbourne, kent | |||
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Expert Posts: 2812 Location: Bournemouth | You seem to forget who I am | ||
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Expert Posts: 2029 Location: sittingbourne, kent | djwilma - 17/4/2015 2:44 AM You seem to forget who I am nope just the person in my rear view mirror from what I can remember? I took my metro for a good blast last night. I haven't got an inlet temp gauge, but I can not get any heat in the charge cooler at all. The water still feels as cold as tap water, so im happy its working better then it did with the gt20 | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Well work is horrible at the moment, oil price is low and sales lower so its been all hands to the pump. So i have had little time to play with the elise I am also moving next week so i thought i would spend an evening on it Bad news was, it blew the new alternator i fitted. So thats 3 its been through now. So its not an earth, not a live, not overspeeding or heat. So latest idea is that its load on the alternator. It blew whilst stationary in traffic at 95C. This is when the water pump duty goes to 100% and the fans kick into high speed. With all the pumps going i think it asked for more than the alternator can give. So a 120amp alternator has been ordered and hope to have it fitted this weekend This time just the regulator, the diode pack went later this time More worrying is that the car wont start, nothing when the key turns not lights off nothing. Thought this was the immobiliser so removed it and bypassed it  Didnt work Thought the starter had blown but live to the solenoid and she runs fine MFRU is clicking when the key turns but starter isnt moving. Thought it was the alarm, so managed to find a 8186 on ebay new and unused. The alarm has been playing up recently too, the fuse to the siren was removed as it was open circuit. Central Locking had failed and the LED on the Stack no longer worked. So today i spent the fitting the 8185 module.....horrible   Finally found the module, thanks to Junks and Sportomotive, it was behind some cheap foam Changed the Module and central locking is fine, led works but engine still wont start. The new immobiliser has a different plug so need to get a wiring diagram LED flashes 7 then 8 times, instructions say this is a Serial Line Data Link....... Pulled the old alarm to bits and found that it had got hot and had blown an electrical component thingy   Had enough and went to collect my son, who asked where the Lotus was and why it was in hospital again Drinking now :bc | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | sounds like a lot of annoying hard to find problems. I hope you get it sorted | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Well this is starting to get on my tits...... Moved house, collected Elise got to my new home and thought i would run up to the next junction as its de-restricted to clear the engine out :bc Foot down in third, big smile, engine lost power......looked at new 120Amp alternator voltage and 13v. Dumped clutch, engine cut out all lights on dash on. Clutch up, and engine revved back up, lights went out no power and no noise. Pulled over, popped bonnet The fuel rail regulator had literally popped off the rail and started to fill the boot with fuel........  Its held on with a stupid clip, refitted and realised the o ring had also gone awol Phone my friends at recovery..........called wife and explained.....got shouted at as house needed moving  Today i received, the wrong, fuel damper. But wasnt too worried as could fit the fuel in to the end of the rail. Released jubilee clip gave it a tug and the fuel rail snapped   At this moment i'd sell the bloody thing as just dont have the time or worse the inclination......as stressy job and just moved house. Rant over | ||
| Marv_666 |
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 '88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Thanks Marv but i have a habit of breaking it, and would be bored if it ran (no i wouldnt) Well work and the house move have calmed down and i have had some well deserved time off so i actually had time to do somethings to the Elise Firstly i Jacked it up on gravel, didnt think this was a good idea, so tested to see if it would hold and it fell off the jack ! I now have a nice jack sized indentation on the drivers side sill......numpty that i am ! Anyway after cursing and explaining to myself its fun when you drive it i got on with things The fuel rail was first, i did some research (text Drew at roverdose, thanks again) and he advised to fit the old style fuel rail as this has the regulator on the end bolted in and not the crap top mounted with a clip.  Was sent one the next day and fitting was easy ish, even if i did have to bend the rear clam to get the inlet off  The alternator wasnt working so i charged the battery and took her for a little spin, came off a roundabout floored it and smelt coolant. Looked out the back window and it was covered in condensation.......parked up got out and......  A small hose from the turbo coolant outlet was touching the turbine housing and had just given up with all the heat Luckily the hose from the header was too long so cut it and re-positioned the new hose and all is well again. I may add a metal extension to take it away from the housing completely.  So the battery had dropped about 0.2 volts in a few mins driving so i thought i would take the car to help my brother start his new engine, only 10 miles away, and arrived with only 0.5v dropped. This tells me its not a short or a faulty piece of equipment as the battery held up well. Charged it up as it was dark when i left  So i purchased another 120amp alternator and had this fitted at the ever Helpful Tech1 Performance in Poole. They are ex Ktec and Paul has done some top class fabrication for me on my metro before and they as a norm deal with Modified cars etc so they were more than happy to help  I also had the Battery tested it was only holding 11.8v and 330ah so was advised to get a new one> Same model and the new one was 12.6v and 550ah I also changed the negative terminal from a quick release to a hard one, just in case. Was in two minds as to whether i should wire up the alternator but changed some settings on the ECU so the FAN and PUMP didnt both come on a the same time and thought what the hell Car made it home but the voltage dropped from 14v down to 12.1v over a 30 min period. Let car cool started again and straight up to 14v battery was 12.4v before starting. So i thought it may be a bad connection so wire the battery straight to the alternator, so a 170amp 120" cable was ordered and "bodged" on  This made a big difference and voltage with everything on i could press or twist, dropped to 12.8v (the DTA Volt meter is a long way down the cable so i expect voltage drop) and 13.2v direct on the battery. This weekend i have done 250 miles in the Elise and no electrical problems. I even managed to convince the Drop Zone owner it would be a good idea to take him for a spin up the runway at the end of the day with the roof off managed the below on low boost setting :bc  So, for now, i am all happy again its even done the 250 miles on half the 60 litre tank of fuel including a couple of high speed runs :clp Only casualty is i now have no front grill, the charge cooler is definitely too small (known from the start) and the placement of the air filter means it sucks in hot air from the engine bay not cold ish from out | ||
