Exige Cup 260 - Restoration and Updates

This is where we proud owners can upload information and pictures of our pride-and-joys (their Exige that is..)
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

As all the carpets were replaced, most of the interior retrimmed etc there wasn't much to clean, but the seats needed doing. 10 years of farts are never a good thing to have in your seats

With my seats I can just rip the cushions out as they are velcroed in
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Wet and drying drivers seat only produced this concentrated ass juice
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I repeated until it ran clear, then did the same for passenger seat

Then all carpets were removed, interior as well as boot and treated
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Using Gtecnhniq smart fabric
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If doing this, spray onto sheeting or a box, as if you get it onto hard floors, you basically create the slipperiest floor known to man. Your wife then falls over, spills her wine and your evening is ruined

I also got some custom made floor mats, as I needed long passenger after removing the footrest plus I wanted the logo

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Now testing all the cabling properly (continuity testing etc was done but best to trial fit kit), before interior starts to get refitted. Waiting on new harnesses and some retrimming of the hard bits I outsourced, but those bits are with a COVID hit trimmer who has been hit hardso my material and trim are stuck at his for the time being!
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andybond
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I shall try this product on our kitchen floor and video the results.

Interior looks fantastic. Please don’t ever park near my car.
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

andybond wrote: Wed Mar 17, 2021 5:02 pm I shall try this product on our kitchen floor and video the results.

Interior looks fantastic. Please don’t ever park near my car.
Seriously the slipperiness on a hard floor is ridiculous , the cats running round the corner lost the backend and spun out. If it wasn't for them breaking the tension I would have been sleeping in the car I think
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thommo
Posts: 4791
Joined: Tue Jul 13, 2004 12:50 pm
Location: Lancs

Very informative (and entertaining) :clap:
Exige S1 No: 139
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

Yet more dull as wiring - progress is still slow and taking place in the wee small hours, so I'm just trying to nibble away at it…

Test fit of the dab stereo went badly, not a single station found on FM or DAB, very very frustrating. Refiting old stereo to prove I had a faulty unit and that worked fine on FM - FML!!

Until I unplugged the arial on the old head unit and it carried on, it appeared to make no different to radio reception if the arial was unplugged or not… So it was broken somewhere.

Thankfully I found the break at this connector under the front access panel - replaced that and all was well again
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Created an extension harness enabling me to switch off the sub and rear view camera
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Under dash wiring now tidied up trying to make sure of no rubbing or annoying rattles
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One thing I noticed when testing the AIM dash is that the logic of lights on buzzer doesn't make sense, if you have the key in light on and open the door, you get a ping. If you take the key out you don't. They may fix it in firmware, but they might not so I thought I should fix myself, but I needed to make it bypassable as I still can't work out if I should out the AiM dash in or not!

Lights on pinger bought:
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Then wired in with two bypass switches - the first defeats it completely, so running the OEM dash I can just forget (seemed sensible as two buzzers are annoying), then a second to add defeat if ignition on allowing you to open a door with the engine on and it not skwark at you . Switches added here:
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You can also see a third switch and LED in that pic, that turns on the USB power for footcam and LED tells me when its on. Camera is set to auto switch on with USB, and start recording at switch on.

Then panel in position
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Looking messy, and I found an old seat cushion from one of those bouncy ikea chairs makes laying in the footwell much more comfy (but not really easy to extract from)
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Various bits of wiring about to be hidden under dash
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Programmable relay added for wipers - allows you to programme wipe interval from 1 - 40 secs (utterly pointless, car doesn't really see rain)
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Wiring all taped up and hidden
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Access hole cut in case for Footcam, pre neaten up, allowing camera to be hardwired - I could have gone frame case but I had this one spare and it worked so why not
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Footcam now in place:
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And the final monumental piece was the dash was put in - after removing just before new year, my car finally has its dash back in!!
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Still waiting for my vents and dash binnacle to be trimmed, trimmer is ill so both the spare parts and the material is trapped at his - worst comes to the worst I stay with the black plastic versions I retained (I knew getting spares had merit)
Shiny new harnesses arrived yesterday, but with the wrong buckle -so they are being picked up tomorrow and wait for another set to come from Germany
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

Toyo UK finally got stock of 205 fronts on the R888r so I have a full set at last - now I have these I can take my spare wheels to be refinished - just booked them in for drop off!
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These are the wheels in question, I'm sure I posted about them in the past but for those that missed it
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They will be refinished Lotus OEM colour, Hi Power Silver - it’s a layered paint process by Feilacke so will be getting Radar wheels in manchester do it. Heres the finish on an Elise to show the look I hope will come out against the red, hopefully I get the same effect
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thommo
Posts: 4791
Joined: Tue Jul 13, 2004 12:50 pm
Location: Lancs

Good progress!
Exige S1 No: 139
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

thommo wrote: Thu Mar 25, 2021 4:40 pmGood progress!
Cheers, its now starting to come together after continually redoing lots of little bits as I keep thinking about slightly better ways of doing it :thumbup:
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MrP80
Posts: 212
Joined: Thu Oct 11, 2007 10:14 pm

Right, so the boot was a bit of a mess - I had done an initial tidy up when I got the car, but knew I wouldn't do it properly until the car was back from paint due to rear clam coming off and all the cabling and oil pipe having to be dragged through

As I mentioned before I found deposits of oil in the carpet, so I knew the Accusump had been a bit leaky…

After speaking with Canton they thought it would be the pressure release valve - if you keep pumping full of oil and don’t' dump it, pressure will rise and it will mist oil. When I got my car I found the accusump wasn't actually wired in in terms of the release valve, so this seems to have been what was happening. Oil kept being added but the valve did not allow it to release so before it blew it released pressure.

As a precaution I changed the control solenoid valve and pressure switch anyway, this is the switch and solenoid in question, well its library pic as I can't find the pics I took of replacing it

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I didn't really know how the Accusump worked before I looked into so here (lots of people make authoritative statements without knowing its basic operation) is an explanation if you are really bored, only reason I mention it is several people have just said to rip it out - but I quite like its simplicity now I understand it. I thought it might be useful when people are trying to work out the point of them

The Accusump is just a simple syringe which fills with oil and has a spring (air in this case), oil is pushed in by the engine under normal running and the spring is compressed

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When the oil is needed due to low pressure in the engine, the valve is opened and the oil is dumped back into the engine to prevent starvation

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This is an augmented view of the Accusump showing the air spring against the 'syringe' head

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When the Accusump is completely empty you need to precharge the system, effectively providing the spring to push against the oil, so the dial even when empty will show about 15PSI

Here is an actual Accusump pulled apart, its all quite smooth with flow of the syringe so the brackets are on the extreme end, putting a clamp in the middle would likely block the ability for the piston to move:
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So under normal operation the oil pumps around and slowly (well within a few secs) fills the tank, so apart from needing an extra litre of oil on fillup you don't notice it
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When low oil pressure coming after the pump is detected, the signal is given to the valve to release the oil and it dumps it back into the fuel circuit, a check valve prevents it flowing back to the sump
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And that’s it really, it also does this just before start up so the engine is preoiled, this is the main reason I have retained it. That and the kids still think I have a can of NOS in my boot after watching the documentary Fast and Furious

In the future I may add a T piece on the pressure guage to put in a sendor, then I can use this to run a guage on the dash so I can seen when I am empty - this is clearly in pointless nerd territory, but then so are most of the changes I made…

Heres and example of the setup I plan to copy
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School lesson over, carpets and mounting brackets all stripped out and cleaning began

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Looms were stripped of felt tape as some were either gummy, or had a some oil - all were stripped then retaped so it was all OEM looking again, wiring itself was all good so no issues to report

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Battery mount was looking a bit tired:

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So was wetsanded and polished:

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Wiring like the alarm switch was tacked in properly, not used gaffa tape like Lotus thought would do

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For those that want to know, here is the Accusump routing out of the boot, the mirror of the wiring harness, and you can also see the reinforcement plate for the wing that I wondered it it existed, it does

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I need a new can of tyre gunk as mine is 10 years old looking at the date, so doubt I can rely on it

Carpets that are now protected, replaced, and trimmed the wheel arches as they just had primer so looked crappy rather than 'because racecar', power feed to cabin added - the yellow and blue cables are camera and reverse signal routed from cabin and will be wired in shortly so will also be out of sight
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I will also be planning out a bus bar arrangement to mount the cables on the battery rather than direct as it was already a bit crowded with the various extra bits, and maybe a LiPo to take out a few more KG's
ade
Posts: 7418
Joined: Thu Sep 21, 2006 10:40 am
Location: Essex

I had an Acusump on my car and even with a baffled sump it was clear it was used, the fact it would have hot oil in it after a session meant it was topping up pressure as required then refilling with hot oil, I'm glad you have left it in
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