DJ Wilmas 111S S2 T series 400bhp Elise

[djwilma]

Bit of a pain but the water pump to the dyno brake broke today so didnt quite manage to get it all done.

Here is the curve for the first curve, timing is now correct but still needs cam timing and more boost but its a nice start.

Boost is rising higher up which I think is the wastegate being to small but its not the end of the world.

Still needs to rev more but its a good base.......hopefully tomorrow but 400bhp looks achievable hopefully more ;-)

[djwilma]

Ok 1.6 bar or 23.1psi in old skool

372lbft at 5000rpm

340bhp at 6000rpm power is dropping off still

Cam timing tomorrow but if it revs to 7000rpm it will do 400bhp

[djwilma]

So cams were checked and inlet was 1.8mm at tdc and exhaust was the correct 0.42mm. Inlet has been corrected and it made another 40bhp. But the dip in power at 6250rpm is still there. It does recover so tomorrow we go for more. But exhaust manifold gasket is blowing so needs changing.

Could be turbine housing but its got no more boost on the 11psi actuator.

So do I up the turbine housing to 0.82a/r and bolt on a 14psi actuator.

Or just accept it will be quick enough with 450bhp per tonne and get it on the road !

[djwilma]

Well things are going a bit slower than I want but few snags on the way

The speedo is now working it has a stand alone pulse converter
The temp gauge now works, thanks arno and rotivator for the help its run off the dta and is now reading the correct temp
Afr gauge has been added to the centre consol

But the oil filter adaptor is leaking as its porous so needs to be replaced

We think the lack of revs is the head, the t series head isnt a wonderful design esp on the exhaust so I have purchased a ported head, some mechanical lifters and uprated springs and will run some piper 285 cams or a custom billet and try to rev to 8k

Car now needs to be shipped off to the body shop to get finished......summer is coming

[djwilma]

So 382bhp and 371lbft just doesnt cut it, actually 6250rpm doesnt. C6 gearbox is just too short so need more revs, may loose a little bottom end but hoping to gain 1500rpm top end

So, i made some enquiries and came up with a plan of a ported and polished head with Mechanical Lifters, uprated single springs and some billet cams.

So i managed to get a head, its been ported but i only paid £200 for it, add to this the mechanical lifters and the springs (same as a k series) i purchased and all i needed was the billet cams

Spoke with Grant at gb-ent and he said £800 plus VAT, Piper said 1200 so i thought long and hard and in the end have sent some cams for a re-grind to Piper 285M via Drew at roverdose. Not ideal but i havent even driven the bloody thing yet !! In fact the only elise i have driven is a 340R, to the end of friends road and back, and a S2 of Junks, where i reversed 20 yards.

So the head malarky, will happen after the summer, car is on its way back as we speak from JDM Dyno in Cumbria so i can enjoy it as its nearly a year since purchase.

Pics of Ported Head, David Bailey eat your heart out



Exhaust



Inlet



Oh and the seats i have are blue and material, as the leather seats were sold, so i bought this drunk off of ebay........



They have a stamp saying 2002 so assume close enough for now

Plan is to get it re-sprayed and on the road within the next 4 weeks........

[djwilma]

I hope so on the porting, inlet looks nice but its the exhaust thats the issue on the T series and i would of liked to see a larger port, or at least some work. This makes me think one of the big boys didnt do it......but its a lot better than the std head

The car arrived home a day early, i was just trying to check in to a flight to Norway (which i missed), when the nice man called to say he was 30 mins away. Long story short my brother met the man and car is now at friends Lock Up awaiting being stripped and re-sprayed.......Starlight Black as per the original car

Engine in, only issue is the throttle cable hits the bonnet, so may need to adjust one of them.......



Nice big Dump Valve



Ickle Bit tight for the turbo but a ahem "Chimney" style heat shield, turbo blanket and baulkhead has been given the heat shiel treatment. Should help, undertray has a massive naca duct in it underneath and engine bay has a 4" in line fan to move air around when stopped or hot...



Charge Cooler, looks like a custom fit.....however its a Fiat Seicento std radiator, which is twin pass, with a modded end tank to take the 19mm tube to the charge cooler



Rear looks fairly std, as it has the original 3" Lotus ends :cool



Vibratechnics engine mount, and a few things in where the wheel arch should go so may need a little move around :beat



Inside the car we added the AFR gauge, the centre consol can do it but easier to look at the MTX, passengers knee may hit it so will remove the wifes right leg if this happens (y)



Front Clam with triple pass Pro-Alloy rad with 2 pull radiators.....charge cooler also has fans on back side for added cooling




AP 4 pot brakes look tiny against the 308MM discs, from a Vectra re-drilled to suit Elise Hub, all under std 111S wheels



Little, bad video, have explained to mate never to rev and switch off the engine again......or i kill him

http://www.youtube.com/watch?v=i2D818jHGfI&fea...

Sounds and footage is terrible so will get a better one later. Its has a resonance through the longer pipe, so blocking this quietens the exhaust.....just in case its too loud i can bung a bung or orifice into it

[djwilma]

GTRene said:

maybe the engine-bonnet
of the Lotus S3 will fit better (higher), gives also more cooling but I don't know if that fits?

may take a look, but i think i can do it by moving the throttle body or a small cut in the bonnet to clear

[djwilma]

Well things slowed to a halt, promotion at work lots of travel and so on have meant the cars been on the back burner but finally getting things done

The throttle linkage needed changing as the m series inlet was fouling the rear clam, now fits underneath



Wiring is a mess so having this tidied up and the addition of a seperate fuel pump relay for the motor sport pump



But the main issue is the front clam. Bodge it and scarper painted it a lovely blue which had gone crazy. Tried to sand it off and it goes too mooch and clogs the paper as they just painted onto the original paint without sanding. Only way to remove is with a scraper which is time consuming





Hoping to have the car complete by end of june

[djwilma]

Well things slowed to a halt, promotion at work lots of travel and so on have meant the cars been on the back burner but finally getting things done

The throttle linkage needed changing as the m series inlet was fouling the rear clam, now fits underneath



Wiring is a mess so having this tidied up and the addition of a seperate fuel pump relay for the motor sport pump



But the main issue is the front clam. Bodge it and scarper painted it a lovely blue which had gone crazy. Tried to sand it off and it goes too mooch and clogs the paper as they just painted onto the original paint without sanding. Only way to remove is with a scraper which is time consuming





Hoping to have the car complete by end of june

[djwilma]

Well this is becoming annoying. Been so busy with work the car hasnt moved on much.

So today I left early and finally did some stuff

The fuels pumps have been wired in on seperate relays now, but on running it up it now has a fuel leak on the old regulator, so have to change the fuel rail grrr



But final got the rear inner arches on



And the front n/s. Am I right with the fusebox and relays ?

[djwilma]

Well this is becoming annoying. Been so busy with work the car hasnt moved on much.

So today I left early and finally did some stuff

The fuels pumps have been wired in on seperate relays now, but on running it up it now has a fuel leak on the old regulator, so have to change the fuel rail grrr



But final got the rear inner arches on



And the front n/s. Am I right with the fusebox and relays ?

[djwilma]

chuntington101 said:

Where have you mounted the radiator for the chargecooler? Looks a very good sized unit and should keep the intake temps down!

Charge cooler is below the rad, it has a gap between it and the rad and has its own fans

Temps today were 38c which i am not too upset with as ambient was 32c


Failure.......this is the word of the day but in the grand scheme of things, and after some soul searching and being told not to be grumpy "its only a car" i have come to terms with the MOT failure today !

It didnt fail on much, i couldnt find the drivers side mirror, the aim on one of the lights is low but worst of all the steering rack is buggered.

So basically the car looks like this now






It needs to be sprayed but my insurance company are threatening to cancel the policy so it had to be done this week.

Here it is on the MOT Bay at K-tec racing, passed the emissions no problems, but it ran out of electricity and has sprung an oil leak.....so off with the rear clam again !



But before all that went Pete Tong we took this video, not be driving as Scott cant use a camera its 20 seconds of your life you wont get back, but even i am thinking this doesnt exist sometimes !

[youtube]www.youtube.com/watch?v=ohsScfjDDK4&feature=youtube_gdata_player[/youtube]

[djwilma]

Yep not far off paint will be next month, need to drive it around to see if everything works.

Well i know the reason the rack felt ok but was horrible to drive / failed the mot

The casing was cracked on the passenger side close to the pinion.....

Luckily i ordered a new rack from the ever quick elise parts, went for the quick rack as it sounded cool so its fitted and feels so much better

Awaiting the plinth for the drivers mirror, apparently lotus only process orders on Wednesday so i have to wait till next week.....if anyone has a spare drivers side please let me know otherwise i will bodge something on for Friday as need to get it MOT'd or the insurance will be cancelled

[djwilma]

Car is now road legal !

Now to sort out lack of electricity and oil leak......exhaust manifold maybe leaking as well ffs

Then get it sprayed, then uprated links and geo

Then actually drive it !!!

[djwilma]

Thanks John T series seems to be a nice engine it does drive well and lots of low down torque. Pulls nicely in top at 2000rpm

Quick update, the alternator belt was on and the connections tight so assumed it was the alternator gone / fubarred

Luckily i have an inspection hatch behind the drivers seat so i had a quick look and managed to get the alternator out, little worried it has no heat shield so will place one on it when back on.

Took it to local alternator checking place (technical term of course) and they span it up and deemed it a working alternator !!!! A little confused they suggested i could of dropped it / rolled about the car and the bushes maybe connecting. I hope so, so i asked them to refurb as i have no idea what alternator it is.



Once the alternator was off i went in search of the oil leak, so off came the rear clam, and found the exhaust manifold was leaking

This is the second one to go so the flange (he he) cant be straight so it will have to come off and be skimmed.......I did tweak the bolts and it has made it better. Oil leak though, seems to be the cam carrier so will have to take off the rocker cover and tweak the bolts. I have a ported and polished head with some wilder cams to go in so may just do it all at the same time but this will be after the Geo and Spray job.....



Bought some upgraded Toe links from Elise Parts too, thought as the geo will be done in the next few weeks i might as well upgrade them.....plus the plan is to get some ZZR's and do some track days

[djwilma]

So its not the altenator, although it did have a leaking diode, put it on and 11.8Vs

So we did the unthinkable and checked the main alternator fuse, and as per the pic below, it was blown.

So we change the fuse and bingo, 12.8v's, then bang fuse popped again. Looks like i have a short circuit and as i hate electronics i have to wait for a man to do it.......arrgghhh

Anyhow the rear clam is being sanded down, primered and should be sprayed by the end of next week.......which i have been saying for about a year so fingers crossed

[djwilma]

Thanks scuffers will try this tomorrow, friend just said the same. ....fingers crossed

[djwilma]

Electrical issue sorted was wrong size fuse should be 80amp and incorrect wire on starter sone reason a red wire is a ground

[djwilma]

Finally things have started to move on the body work, been a nightmare as friend who is spraying (and has been paid to do it, silly school boy error) has been off work for a while with various problems.

But its now promised to be done in the next few days

I have a few electrical issues to sort too, central locking has stopped working, battery is now discharging when ignition is off and also a few mechanical ones

Think as the car is being stop started a lot, the plugs have fouled up as its running on 3 cylinders, and the exhaust manifold is leaking for the second time so i think it was bent when welded and needs to come off. Luckily i have the mechanical cams and ported head to go on so will have to do that sooner than expected.

Just want it finished now so i can enjoy the british summer........doh

[djwilma]

Finally things have started to move on the body work, been a nightmare as friend who is spraying (and has been paid to do it, silly school boy error) has been off work for a while with various problems.

But its now promised to be done in the next few days

I have a few electrical issues to sort too, central locking has stopped working, battery is now discharging when ignition is off and also a few mechanical ones

Think as the car is being stop started a lot, the plugs have fouled up as its running on 3 cylinders, and the exhaust manifold is leaking for the second time so i think it was bent when welded and needs to come off. Luckily i have the mechanical cams and ported head to go on so will have to do that sooner than expected.

Just want it finished now so i can enjoy the british summer........doh