500bhp lotus S1 Exige build...

500bhp lotus S1 Exige build...

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EX51GE R

Original Poster:

1,368 posts

209 months

Sunday 14th August 2011
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another quick update tonight, finally managed to finish off designing the rear uprights. just need to get some new handbrake cables made up to fit with the new spot calipers.






EX51GE R

Original Poster:

1,368 posts

209 months

Monday 10th October 2011
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Hopefully the build can progress now Darren has finished some 'real' work, hoping for some machine time this week.


ezakimak

1,871 posts

235 months

Monday 10th October 2011
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Any reason why you are not doing full depth pockets right the way through on the upright?

would be lots easier and cheeper to machine as you wont need any fancy end mills.

EX51GE R

Original Poster:

1,368 posts

209 months

Monday 10th October 2011
quotequote all
ezakimak said:
Any reason why you are not doing full depth pockets right the way through on the upright?

would be lots easier and cheeper to machine as you wont need any fancy end mills.
Strength, plus cost isn't an issue and i don't care how difficult it is as i'm not doing it wink

bazza1000

294 posts

151 months

Monday 10th October 2011
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It's going to be a monster when its all done! What a top build.

JayK12

2,321 posts

201 months

Monday 10th October 2011
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EX51GE R said:
Torque should be somewhere around 350-375 ftlb, will be revving to 7800-8000 rpm.
Not upgrading the Valve train too if changing cams? You could rev them to 9000 easily with all your upgrades and (valve train).

EPIC work never the less!

EX51GE R

Original Poster:

1,368 posts

209 months

Tuesday 11th October 2011
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JayK12 said:
Not upgrading the Valve train too if changing cams? You could rev them to 9000 easily with all your upgrades and (valve train).

EPIC work never the less!
From my engine builder...

Rpm breaks rods and pistons. You could not rev a boosted k22 to 9k in a million years if you want it to stay together! Even a k20 at this power level would be pushing your luck. The cylinder pressures on the rods and pistons will be insane at 1.5 bar +



Greg_D

6,542 posts

245 months

Tuesday 11th October 2011
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EX51GE R said:
JayK12 said:
Not upgrading the Valve train too if changing cams? You could rev them to 9000 easily with all your upgrades and (valve train).

EPIC work never the less!
From my engine builder...

Rpm breaks rods and pistons. You could not rev a boosted k22 to 9k in a million years if you want it to stay together! Even a k20 at this power level would be pushing your luck. The cylinder pressures on the rods and pistons will be insane at 1.5 bar +
quite, on my boosted mx5, i have actually dropped my rpm limit a bit to help the rods, anything much past peak power and you are wasting your time anyway.

Chris Peacock

815 posts

207 months

Tuesday 11th October 2011
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Heard that the rotrex gives no "whine"... Unlike a jrsc?....


Great build btw....

hondansx

4,560 posts

224 months

Tuesday 11th October 2011
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Awesome. I am a die hard k-series fan (the only one?), but would love to see what this is like to drive.

EX51GE R

Original Poster:

1,368 posts

209 months

Tuesday 11th October 2011
quotequote all
Chris Peacock said:
Heard that the rotrex gives no "whine"... Unlike a jrsc?....


Great build btw....
Yes, no whine...

You can hear the Jackson car, then mine (the last one the camera follows)

http://i48.photobucket.com/albums/f222/lotusman1/a...

Edited by EX51GE R on Tuesday 11th October 21:31

Chris Peacock

815 posts

207 months

Tuesday 11th October 2011
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^^^^^^^..... that sounded great, love the small bounce off the limiter....

EX51GE R

Original Poster:

1,368 posts

209 months

Tuesday 11th October 2011
quotequote all
Chris Peacock said:
^^^^^^^..... that sounded great, love the small bounce off the limiter....
Thanks, watching that makes me miss driving it so much, can't wait until it's finished!

JayK12

2,321 posts

201 months

Wednesday 12th October 2011
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EX51GE R said:
From my engine builder...

Rpm breaks rods and pistons. You could not rev a boosted k22 to 9k in a million years if you want it to stay together! Even a k20 at this power level would be pushing your luck. The cylinder pressures on the rods and pistons will be insane at 1.5 bar +
Ah your stroked 2.2. A K20 with 500hp will rev to 9000rpm with the right spec and build. Yeah the pressure will be high thats why your upgrading the rods and pistons. I rev a 2.2 H22 which again is really hard to rev, to 9200rpm on curent 1.3bar make 500hp. They will stay together.

I just find it a shame when we have to drop the rev of a VTEC motor for boosting, im a hardcore VTEC lover. lol.

EX51GE R

Original Poster:

1,368 posts

209 months

Sunday 16th October 2011
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Upright being milled...


EX51GE R

Original Poster:

1,368 posts

209 months

Monday 17th October 2011
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We have an upright...


Chris Peacock

815 posts

207 months

Monday 17th October 2011
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Nom nom nom....

Baked_bean

1,905 posts

191 months

Tuesday 18th October 2011
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impressive work! beautiful machining.

Smokin Donut

272 posts

225 months

Saturday 22nd October 2011
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This is going to go like a scolded squirrel, great project!

anonymous-user

53 months

Saturday 22nd October 2011
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EX51GE R said:
We have an upright...

Looks good! Have you done any FEA on the Upright? (it's always a bit of a 'mare trying to decide on sensible load cases, and also why OEM's still do "kerb strike" tests etc even after lots of FEA/FMEA work ;-)