2006 Exige S

This is where we proud owners can upload information and pictures of our pride-and-joys (their Exige that is..)
Fonzey
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Re: 2006 Exige S

Post by Fonzey »

When I first dismantled the car I put part of the rain shield/gutter thing to one side as it was looking grotty.

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This is partially visible when the clam is back on, so worth spending a bit of time to clean it up.

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It's maybe a bit shinier than I expected... probably should have gone for a satin grey instead to keep it looking OEM but it should still look rather sharp when the car is back together.

I've got my CC hoses routed a little differently now, as a reminder this is my initial route:

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Adding the infamous AC pipe has crowded things a little and it was too difficult to route the pipe without straining something.

Introducing a couple of 90degree elbows has done wonders though:

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There's now plenty of room for the AC pipe, sort of - it makes contact with the CC return pipe in a couple of places but once it's properly connected in I should be able to resolve that with a bit of gentle manipulation...

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The only (quite big) thing I've not tested yet is clam fitment with all my new extras. The back of the headlight pod is likely to be my area of concern as it runs very close to the oil cooler feed which I've used as a guide to run my CC inlet. From looking at a photo I took upon collecting the car last year, I think I've left enough room...

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I'm now debating whether to follow through with the AC guy and get it gassed up in my garage, or get the car back road worthy now and just take it to a generic place to get gassed up. The latter is likely to be cheaper, but if I get the system pressurised in the garage at least we've got an opportunity to address any leaks whilst the clam is off...

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andybond
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Re: 2006 Exige S

Post by andybond »

I would use the specialist. He will know his onions and likely get you a fast, reliable solution.

We should have a celebratory drive out!

Fonzey
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Re: 2006 Exige S

Post by Fonzey »

Yeah I'm a fair kind of person too. He's been running around trying to source fittings etc, and will be a minimum of two round trips to my house so I'd like to do SOME business with him as a gesture.

Celebratory drive out sounds ace, hopefully won't be long now!

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6970K
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Re: 2006 Exige S

Post by 6970K »

Nice work Kyle

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andybond
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Re: 2006 Exige S

Post by andybond »

Fonzey wrote:
Fri Jan 31, 2020 3:56 pm
Yeah I'm a fair kind of person too. He's been running around trying to source fittings etc, and will be a minimum of two round trips to my house so I'd like to do SOME business with him as a gesture.

Celebratory drive out sounds ace, hopefully won't be long now!
Be worth noting all the bits that are replaced and offer a Fonzey Fix It Kit?

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thommo
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Re: 2006 Exige S

Post by thommo »

Really enjoyed following your progress. That reminds me, I must try to finish my bike restoration . . . it was supposed to be finished last spring but somehow never got round to it. :roll:

Fonzey
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Re: 2006 Exige S

Post by Fonzey »

andybond wrote:
Fri Jan 31, 2020 5:42 pm
Fonzey wrote:
Fri Jan 31, 2020 3:56 pm
Yeah I'm a fair kind of person too. He's been running around trying to source fittings etc, and will be a minimum of two round trips to my house so I'd like to do SOME business with him as a gesture.

Celebratory drive out sounds ace, hopefully won't be long now!
Be worth noting all the bits that are replaced and offer a Fonzey Fix It Kit?
As it's worked out I'll probably be replacing nothing... it's really looking like the OEM pipe will be a fine fit now, I just don't want to button it up until the AC guy gets here (if he ever gets time) in case he finds a leak elsewhere.
thommo wrote:
Sat Feb 01, 2020 12:15 pm
Really enjoyed following your progress. That reminds me, I must try to finish my bike restoration . . . it was supposed to be finished last spring but somehow never got round to it. :roll:
I get motivation from reading other threads from people with much bigger jobs/tasks to do than what I've got. I'm glad you've enjoyed reading, I always enjoy revisiting my threads a year or two down the line which is the main reason I write them... if somebody else enjoys the journey then that's just a bonus.

I had a little bit of progress this weekend but really running out of jobs to do and it's upsetting me. Brother in Law came round to have me change the oil in his Civic Type R so I used the opportunity of a spare pair of hands to give the brakes another bleed through and also managed to fix a creaking clutch that I've had since buying the car. It was a bit too awkward for photos, but the sound (when sat in the cockpit) sounded like it was coming from the pedal assembly, but once I was laid under the car with my helper pushing the clutch pedal I could clearly hear it coming from the clutch fork.

Nicked a photo off the internet:
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Once I pulled back that boot, I could finger in a gob of grease into the pivot point and it cured it immediately. Just hoping now that it's not possible to contaminate the clutch surface from there... I really don't know the anatomy of a gearbox at all. :roll:

Ride height is just about in the ballpark now, but still scrubbing on the OS wheel arch liner on full lock but I think this might be cured once the clam is fitted and the arch liner is 'bolted up' a bit. We shall see.

Brakes still have air in them, I knew to expect bleeding to need a few runs through after having the calipers totally emptied as they're notorious for it. I've done the "turn the calipers upside down and bang them" method and the car is just about driveable now so once the clam is on and it's taxed I'll see if I can invoke ABS a few times to clear any lingering bubbles out of the ABS system, then give it (hopefully) one more bleed.

Fonzey
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Re: 2006 Exige S

Post by Fonzey »

Wooo updates!

I had a date booked with my AC guy and we'd both agreed that either AC would be working, or the whole lot was coming out and going in the bin by the end of that day.

As a reminder we had three AC pipes to choose from...

1- The one I butchered from the car, probably the worst condition.
2- A donation from a fellow enthusiast (https://www.instagram.com/biggerome/?hl=en). This was intact, but the tab end of the condenser was still stuck in the threaded portion (the same portion I removed from my own)
3- An offering from Elise Spares, visually in perfect condition and kindly shipped to me for a nominal fee.

The solution should have been simple, attach up pipe #3, check for leaks and regas. Sorted... unfortunately there was a sting in the tail to this job. Little did we know that pipe #3 had a bit of condenser thread stuck in its own threaded attachment. A very small sliver, almost impossible to see from the outside so when we wound the fitting onto my (brand new) condenser it went on fine for a couple of threads and then started binding up....Bit of panic and a quick chase down the condenser thread with a die to tidy it up afterwards...

Due to the captive nature of the compression o-ring fittings there's no way of replacing or repairing this thread so we faced a choice...

1- Force it on, knowingly (probably) damaging the thread on the new condenser but hopefully getting a good seal and hoping we never need to touch it again.
2- Back to plan A, and fabricate a new pipe.

Obviously we went with #2 and knocked up a new pipe. It was made from donor sections from pipe #1 and pipe #2, and then a flexi portion put on with a new shiny fitting for the condenser end.

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Pipe #3 is still untouched, I'm thinking of ideas to try and restore it in case somebody else has a similar drama in future. I think if I bought a 3/4 UNF threaded pipe made out of something hard - I could grind a slot down it essentially turning it into a 3/4 UNF hollow tap/thread chaser and use it to clear out the fitting thread. Side project for another day.

Stuart (My AC man) then pressurised the system with nitrogen up to about 10bar and we patiently waited for leaks. Aside from the new pipe I had refitted a fair big chunk of the AC system over the last month or two so I was expecting something to leak... but nothing apparent.

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Once leak checked, Stuart pulled a vacuum in the system for about half an hour, again checking for leaks but mainly just boiling off any moisture before we finally gassed her up. It was around 5.5deg C ambient in the garage and we had the face vents churning out a rather crisp 1.3 degrees C! Success! Rad fans all kicked in as expected for the AC to function, everything checked out.

I had one more distraction now before the clam could go on. I had a chipped driving light which although still fully functional is a bit fiddly to replace with the clam on... I was loathed to buy a new one because the damage was so minor, but eventually gave in.

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Unfortunately now due to the road-rash of the other "good" one, I've got a bit of a mismatched set! Hopefully a few road miles resolves this... but might try a glass polishing kit on the old one to brighten it up a bit.

With that sorted, it was clam time. Had a good friend come over to lend a hand and we nervously offered it into place. I was nervous about CC hose routing and AC hose routing but I had nothing to be concerned about as the clam dropped into place perfectly.

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I put a few of the fasteners in loosely and rolled the car back into the garage to be finished off later (still not done...). The panel gaps weren't amazing before I took it off so I wanted to address as much as I could. I took the door hinge covers off and reclaimed about 1kg worth of mud, gravel and tyre rubber which gave me some more options for fitting it all back together with some nice gaps. I'm just about there, so just need to tighten everything up and get the light clusters in now.

I made a comment on @andybond thread about ride height. I'm set to 130r/120f but it still seems a bit too low to me at the front.

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In hindsight this is on an almost completely empty fuel tank and with no driver in, so I'm going to raise to 130/125 and see how that looks. It'll be getting properly Geo/Corner balanced anyway I'm just trying to get it in the ballpark for a safe/comfortable drive to wherever I go to get it sorted.
Last edited by Fonzey on Tue Feb 11, 2020 10:06 am, edited 1 time in total.

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andybond
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Re: 2006 Exige S

Post by andybond »

Your car does look like its on its knees at the front. I havent been into the garage to get the car out yet, but should be heading out at lunch so will check then ..

Update : 105mm at point A , 110mm at point B @Fonzey

Fonzey
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Re: 2006 Exige S

Post by Fonzey »

Cheers Andy, mine's definitely higher than yours then :crazy:

I know you've not been on track yet, but is the car significantly lower than when you last went on track? Even on standard ride height I had issues with the arch liners at the back of the headlamp assemblies (on my Elise too) when really lobbing it into corners like the Mountain @ Cadwell so I'm nervous of going too low, especially with all my new plumbing tucked up in there!

That said, I guess the stiffer damping will mitigate and control the body roll better, so maybe that cancels it out?!

As a small update, we have light!

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Slowly cobbling bits back on, wasted way too much time fidgeting with panel gaps but I'm happy with them now. Light pods are all in, tidied up the DAB/FM aerial antennae and replaced a bunch of nuts/bolts with freshies.

I'm going to crank in an extra 5mm of rideheight just to play it safe and then do a final spanner check on the suspension before the cars goes on its wheels. Might wind in a bit of toe on the OS front too as I can see by eye that it's out by a mile :lol:

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