Exige S1 project by Klaus

This is where we proud owners can upload information and pictures of our pride-and-joys (their Exige that is..)
User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Tue Nov 07, 2017 10:29 pm

Thanks for all the kind comments :thumbup:

In order to register a car in Germany you need to pass a technical examination called TÜV (just like the MOT).
First problem at the MOT station was to get the car onto a lift. To my surprise the workshop had no drive on lift but only the ones using four lift arms.
We had a hard time trying to get the arms under the car until I decided to remove the diffuser to get access to the lifting points at the subframe.

Second and bigger problem was the validation of the technical data. At this stage there are no papers with the cars except the COC paper which I have bought from Lotus. This paper is the golden key to register a car here in Germany. Without a COC it could be very very difficult to register it.
The engineer at the MOT station was very friendly and as the car is in a good technical state there was no real problem. Until the moment he checked the tyres and realized that the front tyres where of the wrong size. Of course the car is wearing the correct 195/50 16 front tyres but in the COC paper the size was given with 195/55 16! I told him the COC paper is wrong here but he wasn't impressed.

Being eager to help with the problem the engineer was able to download the full 30 page 'EC Type Approval Certificate e4*98/14*0008*15' paper from some non-public government site. And there the tyre size was given with correct size of 195/50 16. Bingo.

So Lotus managed to mess up the all important COC paper of at least my Exige :(

So my car passed the examination without any faults and the engineer added a comment for the registration council to use the correct tyre size in the final registration document.
When registering the car last week I took all the papers with me but it didn't help. The lady at the registration council was not convinced and refused to use any other tyre size than the one given in the COC paper. So I need to contact Lotus to give me a new COC (unlikely) or some paper explaining their mistake.

At least the car has been registered which is a very very important step for me. With such an exotic car like the Exige S1 you're never sure that everything will work out until it is actually registered.


Image

Image

Image

User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Thu Dec 07, 2017 7:46 pm

As mentioned in my 'drivability' thread the clutch system leaked at the slave cylinder. I discovered that it wasn't the slave cylinder that was leaking but the last part of the clutch line. The rigid steel line has cracked just below the flare that is screwed into the slave cylinder.

It is a very special piece of a short rigid lining with one hollow screw of size M12x1.0 at the slave cylinder side and the other end of size 7/16 UNF 20 at the braided lining end (which is of size AN-4, teflon lined). Instead of fixing it in the original way I decided to switch to a banjo bolt/hollow screw solution just like the replacement lines sold by some suppliers.

As I had also trouble tightening the same flared screw at the clutch master cylinder I did replace that one too. I just cut the braided line using an angle grinder and fitted an AN-4 terminal.

Image

Image

User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Thu Dec 07, 2017 9:02 pm

Browsing through some older exiges.com threads I found a guide of how to fit gas struts to the rear hood. Due to the photobucket suicide most of the picture were lost.
Anyway I found enough inspiration to choose two VariLift VL-6-150-400 gas struts (349mm length, 150mm throw, M6). I fitted them to the upper end of the finisher panel
using a stainless steel bracket. The hood end of the strut has been fixed using a M6 ball stud.

I reduced the pressure until both struts needed ca. 10kg/100N of force (measured on a scale to balance both sides).
Now when I release the hood using the lever in the door opening the hood opens just one or two centimetres but stays nearly closed. With a gentle lift it opens smoothly until it stops fully open. Very nice and as it should have been right from the beginning.

Image

Image

User avatar
thommo
Posts: 4202
Joined: Tue Jul 13, 2004 12:50 pm
Location: Lancs
Has thanked: 1 time
Been thanked: 11 times

Re: Exige S1 project by Klaus

Post by thommo » Thu Dec 07, 2017 9:54 pm

very neat. just taken mine off . . .

661
Posts: 1411
Joined: Fri Sep 11, 2009 4:36 pm
Location: East Sussex

Re: Exige S1 project by Klaus

Post by 661 » Fri Dec 08, 2017 8:56 am

They look heavy...









:D :D :D :D :D :D :D :D :D :D :D
Graeme

User avatar
jonnyfox
Posts: 9086
Joined: Fri Oct 05, 2007 10:00 am
Location: Brum
Has thanked: 4 times
Been thanked: 10 times

Re: Exige S1 project by Klaus

Post by jonnyfox » Sun Dec 17, 2017 1:37 pm

Klaus where did you get the carpet you have put under the seats from?
Attachments
image.jpeg
#498

User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Sun Dec 17, 2017 2:01 pm

It's a high quality but otherwise ordinary black velour carpet. Nothing special. I cut it to size using a scissor and that's all about it.

If you can't find similar stuff this is the actual product I used: Vorwerk Modena, 'night black':
https://vorwerk-flooring.co.uk/uk/texti ... na2016.opl

Bye, Klaus

User avatar
jonnyfox
Posts: 9086
Joined: Fri Oct 05, 2007 10:00 am
Location: Brum
Has thanked: 4 times
Been thanked: 10 times

Re: Exige S1 project by Klaus

Post by jonnyfox » Sun Dec 17, 2017 6:47 pm

Thanks buddy
#498

User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Mon Jan 15, 2018 9:25 pm

I'm driving the car on small trips (not too far away from my workshop ;) ) whenever the weather is fine. This helps to sort some minor issues.
On one occasion the car just didn't start at all. There was no fuel smell but the fuel pump was priming. I suspect it must have been a faulty crank sensor or at least it wasn't giving a signal. The sensor had been replaced before with a new one and now I did remember that the old one was bent in a specific way.

I switched back to use the old sensor again and had no problem so far. It could be that the gap between the flywheel and the inductive working sensor is too big and that's the reason why the sensor has been bent by a previous owner to reduce the gap. Did anybody encounter similar problems with the crank position sensor?

Image

User avatar
trackrod
Posts: 307
Joined: Sun Aug 21, 2016 10:43 am
Location: Germany
Been thanked: 1 time

Re: Exige S1 project by Klaus

Post by trackrod » Mon Jan 15, 2018 9:29 pm

Although the Odyssey PC680 battery does a great job starting the car even on cold temperatures it was not able to crank the engine for more than one or two minutes.
When trying to connect the jump start clamps I had problems to place the clamp on the isolator switch terminals. There just wasn't enough room in the crowded front compartment.

I decided to relocate the switch to a better place on the RH wheel arch liner. Of course the thick positive leaded needed to be replace with a longer one. There is a two post connector box tucked away in the unreachable, dead zone area behind the dashboard where the new lead had to be connected. To reach it I had to dismount the wiper engine which is fixed with must be the most awkward to reach screw on the whole car. It took a full two hours to get it back on.

Picture shows the f****ing screw:
Image


The relocated main switch on the wheel arch liner:
Image

Post Reply