DJ Wilmas 111S S2 T series 400bhp Elise

DJ Wilmas 111S S2 T series 400bhp Elise

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djwilma

Original Poster:

198 posts

148 months

Thursday 21st February 2013
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RR D-Day is tomorrow !



djwilma

Original Poster:

198 posts

148 months

Friday 22nd February 2013
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Just got the call, didnt have time to do all of the mapping but so far i am more than happy

First proper run it made 260bhp at 6500rpm, but was boosting higher than the 11psi at 14psi

timing was knocked back a little to lower the boost and it made 290bhp at 6500rpm max torque of 281lbft at 5400rpm and torque at 3000rpm was 210lbft :brum

at 2500rpm it was making 7psi, torque is very flat from 3000rpm to 5500rpm at around 280lbft

Should be finished off on Monday, where the boost will get turned up a little more (29psi max) and cam timings will be changed to get it to rev past 7000rpm, preferably 7500rpm

djwilma

Original Poster:

198 posts

148 months

Monday 25th February 2013
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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

Original Poster:

198 posts

148 months

Wednesday 27th February 2013
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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

GTRene

16,369 posts

223 months

Wednesday 27th February 2013
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400...would be some good power for such car biggrin

djwilma

Original Poster:

198 posts

148 months

Thursday 28th February 2013
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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 !

MGJohn

10,203 posts

182 months

Friday 8th March 2013
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Good thread to follow. Any more progress dj?

Great fan of Rover's T16 Turbo. Lots in the family. Here's one of mine. we also have an S2 Elise.


bencollins

3,486 posts

204 months

Saturday 9th March 2013
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great thread

djwilma

Original Poster:

198 posts

148 months

Sunday 14th April 2013
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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

Original Poster:

198 posts

148 months

Saturday 20th April 2013
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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 wink

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

GTRene

16,369 posts

223 months

Saturday 20th April 2013
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the porting looks good, better flow and less restriction.

djwilma

Original Poster:

198 posts

148 months

Monday 22nd April 2013
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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 wink

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 redface



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 wink

GTRene

16,369 posts

223 months

Monday 22nd April 2013
quotequote all
maybe the engine-bonnet
of the Lotus S3 will fit better (higher), gives also more cooling but I don't know if that fits?

djwilma

Original Poster:

198 posts

148 months

Monday 22nd April 2013
quotequote all
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

Original Poster:

198 posts

148 months

Saturday 15th June 2013
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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

Original Poster:

198 posts

148 months

Saturday 15th June 2013
quotequote all
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

Original Poster:

198 posts

148 months

Friday 5th July 2013
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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

Original Poster:

198 posts

148 months

Friday 5th July 2013
quotequote all
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 ?


chuntington101

5,733 posts

235 months

Saturday 6th July 2013
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Where have you mounted the radiator for the chargecooler? Looks a very good sized unit and should keep the intake temps down!

djwilma

Original Poster:

198 posts

148 months

Thursday 18th July 2013
quotequote all
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]