Race Exige from standard Elise…

General Owners Cars
1

As promised…

I�ve been an Elise owner for the last 3 years.
Here is a photo of the almost standard car.
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/1.jpg[/image]

Before four months I�ve decided to convert the car to a race Exige.
First job was to strip it down:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/2.jpg[/image]

In the above pic you can probably see the mount for the steering colounm in the centre�

I tried to make the car as light as possible removing anything that is not 100% necessary, including the aluminium tubes for the heater. I also removed the battery cables that run inside the sill, as the battery will be place inside the cabin. Finally, the S/S braided hose for the clutch removed too, as I preferred to use solid tube for it, running inside the cabin next to the brake line.

I had the picture of a M/S Elise in mind, so started looking for body parts (a few of you probably remember my �wanted� posts).

The first thing I�ve installed was the aluminium fuel tank.
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/3.jpg[/image]

You might notice the Kevlar braided hoses. I preferred these from the usual S/S braided ones as they are much lighter and resist to higher temperatures.

The roll cage and bulk head was the next task. I admit not an easy one�
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/4.jpg[/image]

For the brakes I replaced the master cylinder with two separate ones. I am not sure if the bores are correct, as I might have to change them after I find and install the front brake system. The installation of the master cylinders and the mechanical brake bias in the original brake pedal was a pita, but now it seems that it is working ok. I�ve also connected a remote knob to adjust the bias easier. A 90 degrees coupler was required for this reason. New brake tubes all around had to be done, too.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/13.jpg[/image]

Then I installed the QED dry sump kit, which was easier than I was expecting. At the same time I replaced the cam belt.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/5.jpg[/image]

Then the engine was back on. By the way, the engine for this year is a standard VVC one with 340R throttle bodies running with an Emerald ECU. In the very near future I will install a big bore janspeed exhaust manifold. I decided not to do anything more to the engine for this year. At least I am very pleased by the gearbox, which is a 5 speed Quaife one with straight cut gears.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/6a.jpg[/image]

Impressed by the room between the engine and the new bulkhead!

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/7.jpg[/image]

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/8.jpg[/image]

The oil pump:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/6.jpg[/image]

I had the ECU mapped before I stripped it in Emerald. Unfortunately, the VVC mechanism stopped working at that day, but these guys in Emerald did what ever possible to map it even the faulty VVC mechanism. I had to pick up the car with my trailer, but I when I got home and replaced the VVC mechanism the engine was working perfectly!
Here is the power-torque graph of the engine:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/17.jpg[/image]

I know it does not seem powerful, but hopefully with the working VVC mechanism will be much much better.

Forgot to mention that I decided to change the colour from silver to black� A lot of preparation for the sills and all the rest body parts, but unfortunately the result is not what I was expecting! But I do not complain as I knew that I am not good in painting. I will try to improve it as soon as I finish with everything else.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/10.jpg[/image]

You can also see the holes I cut in order to remove everything �useless� from inside.


About the body parts� I bought a cheap but old � rear panel which required a lot of work in order to be again like new, a new plastic windscreen, front spoiler, side sills, front splitter, loads of tyres, a new � rear panel for the other side, engine cover and many other bits in very good prices. I also managed to find and bought a set of Exige original wheels, plus a good set of wet tyres. I will be looking of at least one more set of wheels as soon as I finish with the car�
Maddog delivered to me the front clam and roof, so the body was complete. It was just a matter of fitting everything.

Maddog�s roof:
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/16.jpg[/image]

Again the roof with the front clam on it!
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/12.jpg[/image]

The oil and water tanks can be seen in this photo, too. Behind the oil tank, on the bulkhead I�ve placed the fuel filter.

I�ve cleaned all the suspension parts, painted them and put them back on. I removed the nylatron bushes (I was pretty disappointed with them as they add too much friction) and replaced them with spherical bearings. It is pretty amassing how easy you can move the suspension assembly (without the damper). I can do it easily with my small finger! Of course the installation wasn�t a one hour job�

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/14.jpg[/image]


I wish I had more photos of the �project�, but I never thought about this. At least I have a few!
One of the latest I have (three weeks old):
[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/11.jpg[/image]

Since then, I�ve installed the rear M/S 295 mm discs, put the rear clam and roof on and managed to connect them. The radiator is also on and so is the front clam. One of the following days I have to order some new fittings in order to complete the fuel, oil and brake lines.

I hope some of you will find something interested in this post so I can share with you the enjoyment of this project. As you can probably imagine, I rather take my time and build a nice car than rush and go and drive it.

2

Thanks George Most interesting, & a great write up of what you’ve done so far. Please keep us up to date.

Thanks again

3

Just when Sean’s is coming to an end (although I’m sure there’s a few more twist’n’turns to go) we get another classic!

And George, somehow your auto porn seems a little more dirty, with the project starting from a ‘girl next door’ Elise.

Ian

4

Fantastic post George.

Sure all your hard work will be worth it, well done!

Now you’ve started, keep the updates coming.

5

Nice!

some good ideas you had there like the bearings in the suspension!
Hope to see some more pictures of your progress!

6

Thank you very much guys for the nice comments.

Today I had just a few hours to work with the car as I received an unexpected email that I have to do an aerodynamics analysis in an air tunnel before this Friday, even if initially I had arranged to do it in two weeks time. So I worked mostly on the model in order to finish it asap. I am waiting now the adhesives to cure before I finish the outer surface and paint it, so I can test it tomorrow morning�

In the mean time, I finished one of the two rear spoiler mounts:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/18.jpg[/image]

As always, it needs cleaning!
It is extremely strong as I used a lot of C/F fabric. But, I think I overdone it, as it weights 1kg! Does anybody know the weight of the original spoiler mounts? I�ll finish with the other side one of the next days, and then I�ll do the spoiler/wing.

I took the following picture to show you the way I am going to fix the hard top at the front:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/20.jpg[/image]

As you can see, I�ve welded three brackets, so I can use bolts to keep the roof in place. For the rear, I am thinking of two latches between the roof and the bulkhead plus two quick release bolts between the roof and the clam. Pictures when I do it!

7

I definitely have to clean it! I�ll put the wheels on, push the car out of the garage and let the water pressure do the rest!

Even the room inside the sill is filthy!

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/21.jpg[/image]

8

Now that’s what the rattle in the sill is

9

absolutely excellent George… never thought i’d see a more stripped down car than Seans…

more pics and details when you get round to is most welcome from me at any rate

Where did you get the spherical bearings for the wishbones ?

10

Looks good George!!!

I love those wing mounts!!

Elise parts do adjustable height ones in ally and they weigh nothing. I have no clue what the standard ones weigh.

Yours look super bling though!!!

Keep the updates coming!!!

Sean…

11

I would never find that nut unless I have taken that picture!

12

I�ve used QA1 spherical bearings (COM10T).
I had to use a reamer to bore out the wishbone housings of the bushes to 30mm I/D. Then with a vice and a suitable socket I inserted the bearings inside these housings. Final job was to cut a 30mm O/D hollow steel tube in small sections, press them in (one at each side) and weld them in place so to prevent any potential movement of the bearing. I also had to fabricate 32 spacers.
I will try to post some pics later.

I just hope it will work on the road as I imagine. To be honest, I didn�t have any wishbone movement problems as I used to use the Nylatron bushes from Elise Parts. The only issue I had with those was the very high friction they added to the movement of the suspension.
I will provide more feedback about this as soon as I try them on the road. The only downside I can imagine at the moment is that I expect them to be very noisy�

13

Thank Sean. I will try and finish the right hand side wing mount the next days and put both on the car so I can see if they are functional or not.

Last days I was so busy with a project I had, that I didn�t really had time to work on the car. I only spent a few hours installing quick release � turn fasteners to the sides of the front clam, so it can be removed easier and faster.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/22.jpg[/image]

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/19.jpg[/image]

Just finished with that aerodynamics project I had and I feel so relief!
I am more than happy with the results which I obtained as they completely agree with the ones from my CFD analysis.
My two models:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/23.jpg[/image]

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/24.jpg[/image]

Not that I expect anybody is interesting with this stuff, but I was so obsessed with it the last days so I couldn�t resist sharing it with you!
By the way, this is the air tunnel I tested and improved a section of my wing! Now it�s just the matter of finding time a build the whole thing�

14

excellent George, thanks for the info about the wishbone bearings, look forward to getting more detail on how they work out and also some pics

what is that aero project then ?

15

It was just a brief research about the momentum injection effect. Nothing thar really can work with the Elise/Exige so no good!

I have ordered many fittings and hoses to finish the fuel and oil circuits, but due to the Easter holidays they will not be here before Tuesday.
The last days I fabricated the seat mounts, put in place new fixings for them and installed the seat. I�ll take and post some photos later today.

16

This is one of the bearings I�ve used.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/28.jpg[/image]

And these are the spacers I fabricated. Simply design, but finding the correct dimensions wasn�t an easy job.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/29.jpg[/image]

Generally, it was an easy and inexpensive job to be done, but very time consuming.

17

And before I forget again, the seat:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/27.jpg[/image]

It is really a weird feeling seating in the middle. I guess I�ll have to get used of it.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/26.jpg[/image]

You get the feeling that this chassis had been build with the idea of using only one seat as the space at the sides is not really big.
Getting in and out isn�t as difficult as I imagined. (at least with the doors removed!)

18

nice one George

I take it that you fit one of the spacers on each side of the bearings when its fitted into the wishbones ?

19

Yes, of course. I made 32 of them.

20

Thought that during Easter I�ll have more time to concentrate to the car, but what really happened is a different story!
Anyway, I�ve managed to finish with the oil circuit. I�ve changed the original QED oil hoses (which were rubber Aeroquip ones) to Goodrich Kevlar braided. Reason for this change is because I was too afraid of these hoses (max temp 100 Celsius) running just a few cm behind the exhaust manifold.
I also made a bracket and by using two bulkhead connectors I mounted these (two) hoses to the chassis.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00259.jpg[/image]

You can see what I mean in the above pic. The two hoses on the right go to the pump and the other two (on the left) to the tank.
You can see the position of the hoses in the following pic.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00260.jpg[/image]

Many hoses run to and from the oil pump and everything is very tight there. Especially one of them was very close to the mount of the wishbone (as you can see)

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00264.jpg[/image]

So, I�ve changed the original setup in order to give more clearance. For this reason, I had to bend accordingly an aluminium tube (as both the Teflon and rubber hose could not be bended so much.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/SOON.jpg[/image]

Now, the clearance from the wishbone mount is significant.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00272.jpg[/image]

Finally, for extra heat resistance I�ve used an aluminium sheet and placed it between the hoses and the exhaust.

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00268.jpg[/image]

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00269.jpg[/image]

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00266.jpg[/image]

So, finally everything in place:

[image]http://i69.photobucket.com/albums/i48/GeorgeLotus/DSC00271.jpg[/image]

Now, the only thing I have to do in order to finish completely with the oil system is to adjust the oil pressure. But, I think this has to wait a bit!