2006 Exige S

Small update, finally pulled my finger out and bought some tyres for my spare wheels.

Went for AD08RS. I’ve been paralysed by indecision for ages now, looking for a unicorn tyre - but this is as close as I’ll get in S2 sizes I think. I’ve gone for a slightly experimental size setup too, fronts are 205 wide and rears are 235 wide (ZZRs are 195 and 225). Lotus fitted this wider size to later S3 Elise Cup cars (or at least, they did on the 260) which I didn’t realise, and I stumbled across a couple of people running them on S2’s too so we’ll see how that works.

The ZZRs were a pleasant surprise at Anglesey in the downpour, but they still have that cloud of uncertainty over them as soon as the water starts pooling up. I feel particularly irresponsible driving them on wet motorways too, especially because the M62 drainage seems to get worse every time I’m on there… so this now gives me an option to fit some wheels more weather appropriate, but hopefully still stand up to the abuse of a dry day if the weather makes a miracle turnaround.

Really interested in your feedback Kyle - I am looking at the NS2R and the AD08RS for when I need new tyres - but for me they are for fast road use - road trips etc. Thought the Nankangs were it, but then folks have said they are very heavy - plus mixed reviews of the RS’s

I probably can’t be too useful as I’ve never run a ‘similar’ tyre before on an Elise/Exige - I’ve used ZZR almost exclusively till’ now. I’ll do my best though! Will likely stick them on for some road mileage this month. :thumbup:

It’s been a busy few weeks on the car… just not for me for once!

I took the car back down to RRR Engineering after I fixed the alternator for them to look at ‘completing’ the ECU install. I say ‘complete’ because it was always the intention to add a few more sensors and more importantly, the ADU digital dashboard. We couldn’t do it last year as there just wasn’t a shroud solution I was happy with, but RRR have figured something out and used my car as a bit of a model/template for future shrouds - so I hopefully there will be some “Lotus-ready” plug and play options available in the near future.

More on the dash later, but I had one complication first… an evening trackday popped up that I’d half-forgotten I’d booked and collection day for the car ended up being on the same day. Luckily the trackday was an evening session, but it meant setting off for the train station with all my trackday gear in tow :laughing:

(yes that oil did leak and ruin that suitcase)

I have to admit I was a little nervous about seeing the dash install in the car. RRR prep a lot of race cars, and do a good job of it - but the fit/finish that I was hoping for is probably something that a racing application simply wouldn’t care about. Probably a bit harsh/unfair to assume they wouldn’t do a good job of it, but I was expecting it to be something that I’d maybe need to tweak or rework myself in future perhaps with some trimming etc. As it came out, I’m chuffed to bits with it.

Terrible picture, sun was everywhere - but it’s the only one I currently have of the screen powered off:

As for the dash itself, the last few years have been pretty big for Lotus fitment digidashes. I loved the idea of the GARW project and tried to buy into that a few times, but due to stock and lack of comms it never really happened. Then the AIM stuff landed which is bloody brilliant and stepped the game up again but for me it was always going to me the ECUMaster ADU once I’d bought into that ecosystem because it adds a fair bit of functionality to my ECU and it’s 100% customisable. Whether or not I’ll ever use that functionality is an argument for another day :unamused:

The headline and main benefit is that it adds a tonne of extra inputs/outputs that the Lotus loom doesn’t have capacity for at the ECU end. Because my ECU is a 2zz PnP one, it is a one-to-one match to the wiring harness, which means you can only add sensors on pins that Lotus/Toyota left free in the standard loom… which wasn’t much. My gearbox oil cooler pretty much maxed it out which is why I had the separate SPA Design oil temp/pressure gauge rather than having it logging to the ECU.

With the extra inputs granted by the ADU, I’ve added the following:

  • Oil Temp
  • Oil Pressure
    (SPA gauge is now retired and I have a face vent back, wooo!)
  • 4x Wheel Speed signals piggy backed from the ABS system
  • GPS position/speed/gyro/etc

These can all terminate to the ADU, and then the ADU sends then as CANbus messages back to the ECU and it all works a treat, so now I can look back at my trackday logs and see how oil temps/pressures were at various places on track. The track day analysis stuff is something that I plan to have a LOT of fun with.

Obviously it also does lap timing, if I participated in track events where this was legal it’s something I’d probably enjoy, but I don’t, so I won’t. IF I did though, it has the popular tracks pre-set into the device and will automatically detect them when you cross the start/finish line and automatically start timing with predictive times/deltas etc. If it’s an unknown track, you can either upload the coordinates of the start line in the ADU software or use a dash button as you cross the line on your sighting laps.

The individual wheel speed sensors gives me the option to use proper traction control, the previous strategy was RPM based and would just look for unusual spikes in RPM and frankly it sucked. No way could you rely on it to drive hard in any kind of dodgy conditions. Now I can set proper slip targets and combined with a 10-way adjustment knob I can have varying levels of aggression for it. It’s definitely something I’ll need to tweak and play with on a wet track and unlikely to factor in on a ‘normal’ day as the car still feels over gripped in most circumstances.

The last core feature is the fact it’s completely configurable in terms of the dash layouts, pretty much whatever you can think of you can setup with a bit of imagination. It’s very flexible and has some good logic built in for configuring alarms and stuff like that (such as oil pressure warnings if RPM exceeds a certain level, AFR warnings at 100% TPS, etc etc). RRR configured the dash with a generic ‘race mode’ one which I think is fairly standard across the range, and their interpretation of a Lotus OEM-style one which I really like for road use. I have tweaked both though, decluttered on some information I didn’t need/want and added some that I did, knocked some of the ECUMaster branding off of it and tweaked some behaviour like the shift lights etc to be a bit more wannabe F1 driver.

These are the screens I currently have setup:

Road:

Race: (since debranded the ECUmaster background)

Diagnostics: (since swapped fuel pressure (not monitored on 2zz) with gearbox oil temp)

I’ll probably add another screen in the near future for ‘tuning’. RPM, Speed, Knock Sensor and AFR Sensor readings etc.

The out of box dashes were pretty good, and really quite usable - but half the reason I bought this was to have something else to mess about with. The only issue with the out of box screens was that the ‘race mode’ RPM bar only went up to 8k, but the shift lights were set correctly for a 2ZZ limiter so it wasn’t a major problem.

In terms of physical inputs it uses the pre-existing button for resetting the trip computer for swapping pages (press), identifying a start line of an unknown track (hold) and acknowledging alarms (press). RRR added a rotary switch for the TC adjust, and also there’s a USB port mounted away for the data logging.

Back to the story, I collected the car from RRR and after a quick training course set off for Cadwell. I was booked on for track time starting at 17:30.

Trackday went well and the new dash didn’t throw any niggles… apart from one very minor one when I filled up with fuel, the fuel bar went to empty rather than full, but over the first mile of driving it filled itself back up again. No doubt some ‘noise filtering’ going on and something I can tweak out, but other than that the fuel gauge behaved impeccably all night.

I’ve not been to Cadwell in an age, and never in this car - so unfortunately I didn’t really get up to speed properly but I enjoyed it nonetheless. I screwed up the schedule a bit and thought the trackday ended at 20:30, so I went out for my final session at 19:55 just in time to see the 20:00 chequered flag :laughing: That was a bit gutting as I’d had an extended break leading up to that to let everything cool down properly for one last go.

It was bloody hot though, I think I took 12psi out of my tyres after the first session and my GoPro was really struggling. Dismounted it to charge it between sessions and it was unbearably hot to the touch and I later found that it was only recording the first few minutes of a session which was a bit annoying. Starting to fall out with GoPro a bit now tbh, done three trackdays this year so far and haven’t had smooth sailing on any of them yet with regards to footage.

Photographer did a decent job though :thumbup:

Oh, and I melted/lost another two centre caps. :cry:

Ill be following your dashboard exploits with interest!

Were you getting front wheel airborne on the mountain? Certainly looks like it!

[quote=andybond post_id=246862 time=1623014614 user_id=27847]
Ill be following your dashboard exploits with interest!



Were you getting front wheel airborne on the mountain? Certainly looks like it!
[/quote]

I’m sure the photographer was photoshopping in air-gaps to make people feel better :lol:



This is about as good as my footage gets I’m afraid: <LINK_TEXT text=“- YouTube … zeyOnTrack”>Lotus Exige S2 at Cadwell Park - YouTube</LINK_TEXT>

Enjoyed the Cadwell Park vid. Never driven it and don’t think I’d ever seen a full lap on film. Quite fancy a go sometime

Good vid.

Car sounds great, not like an Exige should, sounds quite deep and beefy, lovely exhaust and induction sound with a hint of supercharger whine. :thumbup:

Cheers gents, I’m cheating a bit with the sound - the video is overlaying sound from both inside the cabin and from the rear facing gopro mounted to the number plate plinth right next to the exhaust.



If I just use a front facing camera, it’s just dominated by the SC unfortunately:



Lotus Exige S at Croft Circuit - YouTube



If my car sounded like it did on the Cadwell video from inside, I’d love it!



It’s a real shame I didn’t capture much from the later sessions at Cadwell, despite being an evening with limited running, it was really quite quiet and I got some good laps in on a clear-ish track. Plenty of trackdays coming up, so fingers crossed I can get some decent footage in.

I’ve pretty much settled on a dash config that I’m happy with for now, no doubt it’ll change again after a few trackdays.

The aesthetic is largely the same, knocked off the ECUMaster branding and changed a few yellows to blues. Reconfigured the shift lights to be wannabe Lewis Hamilton (GGG, RRR, BBB rather than the default GGG, AAA, RRR) and decluttered some stuff that I didn’t need.

In addition to that I’ve set some alarms/functions up:

  • Gearbox oil exceeding 105deg C
  • Lambda exceeding 1.0 whilst TPS is above 95% (mainly to warn me about sensor failure)
  • Coolant above 105deg C
  • Oil Temp above 100deg C

…and then I’ve got a wee blue light on the dash to tell me the engine is ‘cold’ if either coolant or engine oil are sub 60 deg.

Had a bit of a play with CANbus streams too, impressive how much data I can retrieve so there’s still some room for learning/tinkering to come.

Final thing, I’ve been keeping an eye on my logs for TC activity just so I know what to look out for if/when I ever start using it in anger (wet trackday maybe?). In its most aggressive setting on the road it is kicking in a fair bit but it’s very, very subtle. It just trims a little bit of ignition advance which is barely perceptible in the car (if at all) which gives it a lot more potential than the agricultural fuel cut of the previous setup (though it will implement fuel cut at higher levels of slip). Considering slip events on the road last fractions of a second, it’s amazing to see how quickly it responds, matches the slip target and then gets you on your way. My current slip targets based on the 10-way rotary generally go from 5% at 10, to around 11% at position ‘1’, but gear, TPS and vehicle speed all factor in with their own multipliers too so it will slip more or less depending on those.

I took the car over to a local ‘cars and coffee’ type event at the Motorist Hub halfway between York and Leeds. It’s really gained popularity since opening a few years ago and now has massive attendances most nights.

A fellow owner got a couple of snaps for me as I was too busy eating.

Good turnout, some nice cars to look at but a gaggle of TVRs turning up really did turn my head and made me wonder for a brief 10mins what I’m doing messing around with 4bangers all the time :unamused: :mrgreen:

The dash really looks like a trick bit of kit!

That’s looking awesome Kyle! Well done for trying out something different too - the dash looks like it’s seriously customisable! :thumbup: I wish I could do something to make my AIM’s shift lights a bit more visible - they’re too high in the binnacle and you basically can’t see them because of the steering wheel, lol! I’m assuming you don’t have that issue with your dash?

No I’d heard about the AIM visibility issues so it was one of the things I wanted to avoid. The ADU is available in 5" and 7", the 7" will just about fit into the shroud but you’d have similar issues so we went ahead with the 5" - so the downside is that it does have a smaller amount of screen real estate, but everything is a compromise I think.

The AIM is a fantastic bit of kit and I’d have almost certainly gone that route if I was on the stock ECU still, but it just made sense to further my investment into the ECUMaster ecosystem with this dash - it complements the ECU so much and adds so much extra capability, it was a no brainer really. The only delay was lack of plug and play loom and shroud, both of which AIM had available from the get-go.

Couple of updates for the car, just recovered from an exhausting day at Croft - so time for an update.



One of the changes I meant to, but neglected to make to my car during the winter rebuild was machining down the steering arms a bit to give me some more negative camber at the front. Not sure why, I’ve always felt the geometry of the car has been acceptable but when people tell you ‘its better’, curiosity kicks in I guess. I kept putting it off, but with Croft looming I really wanted to try it to see if a stronger front end at speed would give me more confidence into the Jim Clark Esses to take them closer to the ‘flat out’ the car is probably capable of. (spoiler alert: it didn’t).



In the week before Croft, I made the call to buy some aftermarket steering arms instead. They’re nothing fancy, and are known for not offering the -1deg extra camber advertised but still it was better than nothing as I’d run out of time to take my steering arms somewhere.







By keeping my camber shims as-is (just the ABS bracket on the OS and ABS bracket+1mm NS) I gained approx -0.6. If I remove the ABS shims too, then I get closer to -1.0 (0.9ish) but I need to cable tie the ABS sensor wiring to something. I opted to go with the intermediate setting for now, bringing my negative front camber to 1.3 from the 0.7 it had on the standard arms.



The next challenge was toe, if the arms are kept the same and just the shims are modified you can get away without a tracking tweak because the steering geometry remains the same, but these aftermarket arms had a different relative location for the pivot point so my front track was way out. Once again, with no time left I couldn’t go get it properly setup so I got the string out and did by best… thinking it was pretty close (spoiler alert: it wasn’t)



The road test of the new camber setup felt a bit odd, assumed it was my dodgy toe angle so took it to a local tyre fitting place who have some laser gear. They don’t take bookings and for lunch money they’ll at least make sure the car is roughly lined up, they corrected my settings to what I hoped was something like neutral toe at the front (spoiler alert: they didn’t).



Got the car home, it still felt a bit wonky… about ready to throw the towel in and just track it as it was - I found this in a rear tyre.





Bugger…







Luckily I had a pile of spare ZZRs waiting to go, so back to the tyre shop one more time. Car now felt ‘acceptable’, but still a bit vague just off-centre if I was being picky. Despite that though I was pretty convinced the car felt good when heavily loaded up, better than before.



Quick pre-trackday wash and it was time for the big day, the LoT Croft day probably the one I look forward to the most.





I was joined by my neighbour Geoff for the first spectator-legal trackday I’d done since Covid arrived, it was nice to have some of the social aspect back… plus he bought his converted T5 camper which was amazing for pitlane hospitality.







Car honestly felt ‘fine’ all day, nothing amazing but it didn’t feel dangerous or wayward at all. The confidence I was hoping for in the faster stuff just didn’t come, and I was actually a fair bit slower through there than I was last year - so either I’d just not taken enough brave pills that day, or the steering alignment was playing on my mind subconsciously - either way, missed opportunity I think but I didn’t end up in the field, so there is that.







Had a good day despite the lacklustre performance on the quicker stuff, the differential felt great through the complex, fairly confident I’m much quicker through there now. Car tended to understeer through the hairpin rather than spinning up the inside rear as it used to do - but with a bit of practise I could drive around that, turn in on the brakes a bit and get the back rotating - then there was bags of grip to fire me out. Had a few comments from other cars that I was pretty quick out of there in comparison - so seal of approval all round.







Geoff caught some driveby clips, love the sound of this car from the outside… shame I never get to hear it :lol:



<LINK_TEXT text=“https://www.youtube.com/watch?v=0EV7o1c … zeyOnTrack”>https://www.youtube.com/watch?v=0EV7o1cIbbA&amp;ab_channel=FonzeyOnTrack</LINK_TEXT>



And I got some, but not much footage from the gopro too. I’ve had issues all year with my gopros, I think it’s overheating - so I limited its use this time to try and save it. Got a couple of sessions, but missed my last one which had the typically clear and quick laps - but still down on my previous visits, so nothing amazing was missed.



<LINK_TEXT text=“https://www.youtube.com/watch?v=VILxZdN … zeyOnTrack”>https://www.youtube.com/watch?v=VILxZdNNQl4&amp;ab_channel=FonzeyOnTrack</LINK_TEXT>



Really good day despite the niggles, the ECUMaster dash was flawless all day. If you watch the video you may notice a ‘gearbox oil warning’ come up on the dash towards the end of a session, I arbitrarily set the threshold fairly low (though I’ve got no idea where it should really be set??) to make sure alarms were working ok. I’ll raise it for the next trackday. The logs did show that gearbox oil temp steadily rises through the sessions with no sign of stabilising (in fact, it starts to speed up) so I’m pretty sure a cooler is on the cards if I did want to push for longer sessions. We’ll see.



Croft was also the first trackday that I’d datalogged properly with the dash, and that’s been a lot of fun playing with. You can select two laps to compare, choosing whatever metrics I want from the dash or ECU and then when I hover the mouse over a particular point on the graphs, it shows on the track map where the two laps are (represented by the blue and red dots).







In a competitive context the advantage of this sort of stuff is pretty obvious, but for me just geeking around it’s a great window into what the car is doing on circuit and how certain safety/reliability features are performing. You can see the dips in oil pressure for example during the >1G turns, dropping as low as 2.6bar in the Hawthorne chicane. Still within spec for the engine, but still shows a slight weakness in the sump/pickup and you can see how bigger problems could emerge from a longer/sweeping application of >1G.



As for traction control, I didn’t make use of it all day - car had a couple of slippy moments in the hairpin but really gripped up nicely all day. Probably will be a wet day before I get to play with that properly.



Over the weekend I had a coffee morning arranged with some Lotus friends at a local workshop that happened to have laser alignment gear on hand, so thought it would be rude not to stick it on and see how the car was sat…



Toe NSF: +0’15’

Toe OSF: +0’01’



It was supposed to be just on the negative side of neutral, something like -0’01’



:expressionless:



Donington Evening next in a couple of weeks, I’ll try not to feck around with the car too much before then. Maybe Craners will be my first proper test of a higher camber setup.

I think I need some sucky noises in my life. Looked like it went well!

Oooh, let me know how you go on Craners with the car properly setup! I’m getting more wary as time goes by - need to get my mojo back… I think that all this time at home, not driving has sapped my confidence a lot… :confused:

Don’t get your hopes up! Fast stuff has really been a problem for me this year, must be getting too old/sensible.

I think every couple of years I just hit a plateau with my track driving, it’s starting to feel like one of those years. Need to spend some good quality seat time with an instructor I think to ‘get my mojo back’ as you put it.

Mini update, I noticed a bug in the ECUMaster ADU software when doing the data logging analysis. It’s partly my own fault for using a test version rather than the latest stable, but that’s because the latest stable is now very old and misses out on a lot of the features I want to use.

I raised it with ECUMaster via RRR Engineering, and within a couple of days they released a new test version with my very own patchnote to say the bug had been fixed. :mrgreen: Whilst dialogue was open, we talked about some other features in the pipeline and there’s some pretty exciting stuff on the horizon, which I’ll of course post once it’s available and I can have a play for those interested in the development of the dash. :thumbup:

Donington Update

In the days since Croft I was getting an increasingly odd sensation through the car that was starting to make me a bit nervous. After all of the messing around with steering arms, I really could do to get it back to SeriouslyDave (or frankly anywhere that knows what they’re doing!) and get the alignment triple checked. Even if the various backstreet/DIY attempts were successful, I was second guessing it big time.

When discussing this with a friend, an option came up to get my car checked on the morning of the trackday. I took the option gladly, as I wouldn’t have time to get it looked at on any other day.

It didn’t take long to spot the problem, my rear toe link was loose :confused: Seems one of the backstreet garages I’d used for tracking had been messing around at the rear and didn’t nip it up properly. Easy fix, double checked everything was lined up correctly and I was on my way to Donny! :mrgreen:

It was to be quite a social event, a few of my Lotus comrades would be in attendance too (including our very own Mr Bond), but the nature of a session based evening trackday didn’t allow much time for socialising once the clock started!

It was pretty much 20mins on, 20mins off for the duration of the night which resulted in a fair chunk of track time. Far more than I’d get on an open pit lane evening, but it did mean that the cars (and drivers) were struggling to cool down between sessions!

It was my first time driving Donny in the dry, and first time ever on the GP circuit. Track is fantastic, can’t believe I’ve not done it sooner and more often, it really is a gem. I know everybody says it about just about every circuit, but you can’t believe the undulations and profile of the track despite seeing it on video a million times!

First session out was figuring out which way the track went, literally so - the left hand turn to get onto the GP loop came as a bit of a shock! :mrgreen: I do like a good hairpin though, so it was a welcome addition. Second session I had a passenger, started pushing on a little bit but was still over slowing the car far too much for most of the corners. It’s a very fast circuit when done right (so I’ve been told :laughing: )

Third session was cut short a bit due to an unfortunate fire in an S1 Elise, luckily nobody hurt and it seems the car is salvageable - but still a pretty harsh reminder of what can go wrong.

Car was handling well to this point, turn in was strong but there was a bit of mid corner push on the slower stuff. I decided to soften the front dampers up slightly for the final session to see if I could measure a benefit there. The additional camber I’ve added to the front can certainly be felt, there’s a slight light sensation just off-centre which weights up almost immediately when putting high speed load into the front. It seems to have made the transition between grip and understeer feel more obvious too because the steering suddenly goes from very heavy to very light, and that information did help raise confidence a bit.

The final session did feel much better, but it was bogged down with traffic unfortunately. The previous red flag had eaten into our time allowance for this last session so it was all just a bit rammed in - though I did get a lap or so of clear track towards the end. Car felt quite a bit better in the hairpins, so much so that I felt I hadn’t carried anywhere near enough speed into them. Had I had more time, I’m pretty sure I’d have knocked chunks of time off my laps - so makes me excited for next time.

As for Craners and the faster stuff, I bottled it big time - no way was I doing that flat, at least not on my first time there :mrgreen: The car did feel very settled through it though, I carried a fair lick of speed through the initial left hander on a few laps but then really struggled to get the car back left again ready for the old hairpin. Felt like my laps were quicker where I compromised the entry a bit and concentrated more on the hairpin.

Towards the end of each session my dash was warning me about gearbox temp. The Alarm is still set fairly conservatively so I’m not too fussed about it yet, but the logs do show it showing no signs of slowing down and I think some sort of cooler is on the cards if I want to run longer sessions. Interestingly (or maybe obviously?) the laps I did with a passenger generated gearbox temp MUCH quicker.

IATs were really impressive despite the heat, barely got into the 40’s for most of my lapping, but then of course rose up a bit in the pits. It was brutal conditions for hammering a car, but everything seemed to keep in check nicely, so that’s positive.

Oh, and as a bit of a bonus - we bumped into Julian Thompson who was also in attendance who popped into the garage for a natter. Had me a bit starstruck tbh :laughing:

Car has had a quick wash, check over and it’s back out tomorrow for Blyton. I’ve arranged some tuition for most of the day so will be working on technique a bit and hopefully get some help moving my dampers in the right direction. Car feels very good right now, so think I’ve got a solid base - but I would still like to lean on the car a bit more.

Video of the only real clear laps in the last session: <LINK_TEXT text=“- YouTube … zeyOnTrack”>Lotus Exige Trackday at Donington Park GP Circuit - YouTube</LINK_TEXT>



I was hoping to follow Jonny (Red Elise Cup) for a few laps afterwards as we had been tit for tat for a while… but this was the session the had to cut short, so misjudged that :frowning:

I can’t wait to book a day at Donington in the Exige, it’s my favourite UK circuit.