500bhp lotus S1 Exige build...

500bhp lotus S1 Exige build...

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EX51GE R

Original Poster:

1,394 posts

211 months

Monday 7th May 2012
quotequote all
Darren has been busy this weekend smile









he's started on the gear linkage now, which will be billet too smile



rough mock up....



Finished article in solid works...





EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 13th May 2012
quotequote all
Gearbox linkage finished, im sure darren will have these anodised too..








EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 13th May 2012
quotequote all
justin220 said:
Looks awesome!

Strange question maybe, but is it the project itself, or the actual finished project which you are more excited by?

Reason I ask is I always see a lot of kit car adverts which say 'self built' but are then sold with around 1k miles on it.. And they are selling for another project...
Not a strange question at all and one i have asked myself time and again! I have said to darren after this rebuild thats it, no more! I don't mind routine tinkering and if req'd some fettling over the winter, i know there are a few bits darren would like to do but time at the moment is an issue, he is so very busy with real paying work for TTS that he struggles to find the time for the Lotus.
With regards to selling it after it's finished, that is not an option, Darren has put so many hours into this that i fear he may never talk to me again if i sold it! It owes me no money when it's finished so no worries there either, we just want a full TD season to enjoy it!

Marc.

EX51GE R

Original Poster:

1,394 posts

211 months

Wednesday 16th May 2012
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Darren likes Red!....




EX51GE R

Original Poster:

1,394 posts

211 months

Saturday 19th May 2012
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joehirth said:
Just a quick question, is your bed made from billet aluminium too? biggrin
No, but it might be red ! wink

EX51GE R

Original Poster:

1,394 posts

211 months

Saturday 16th June 2012
quotequote all
making the final push to actually put this car back together now.

Have been beavering away on the engine mount kit and its now done and 5 sets sat on the shelf. enjoy the photos smile













oh and the gear link kit for the s2 toyota shifter conversion


EX51GE R

Original Poster:

1,394 posts

211 months

Monday 2nd July 2012
quotequote all
Got a fair bit done this weekend, new fuel tank arrived from pro Alloy (thanks wayne), engine in for the final time on fully finished mounts, got all the uprights finished and on, brakes on, exhaust mounts cut off and repositioned due to a change in engine position...





Still a mountain of jobs to get through though, the list seems never ending ! frown

EX51GE R

Original Poster:

1,394 posts

211 months

Wednesday 22nd August 2012
quotequote all
Not much to add at the moment really, what with my impending marriage and Darren having to work 3 jobs at TTS due to losing their fabricator/welder the project has stalled somewhat frown

However i now have the dash8 fuel rail in hand and i'll be mailing that off to Darren tomorrow so he can get started on the fuel system, he's having a go at refitting the charge cooler system this weekend smile

New fuel rail....


EX51GE R

Original Poster:

1,394 posts

211 months

Saturday 25th August 2012
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[quote]Originally posted by deltav
Ok, a few small jobs taken care of this weekend.

Got the bosh 044 pump mounted up as well as the high flow filter. I didn’t really like the idea of mounting the pump in the side pod in the event of a crash so have found it fits quite nicely in this little gap.


Got a few more bits back on the engine such as starter, throttle body, water pipes and most of the wiring loom.



Took the disk cutter to our charge cooler and made the new fixing brackets that mate up with our new cnc engine mounts



Also moved the air temp sender into the end tank of the charge cooler as it was always a barstard to fit in the hose between the tb and cooler. Also modified the outlet pipe to take it from 76mm down to 70mm so its actually the same size as the throttle body.



Charge cooler all mounted up and I made a start on the new pipe work as the old stuff now doesn’t fit with the biggest supercharger





And that’s about it for this weekend as the girlfriend has ordered me away from the workshop! GRRRRRRRRRR.
[/quote]

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 26th August 2012
quotequote all
Erwin1978 said:
Looks absolutely fab, love the engineering and execution. What will be the car's usage when finished? Track toy? Time attack (it's got the power)? Or road legal super car slayer?
Little bit of both, will be street legal (ish) wink but the geo will be a track setting, along with the rose jointed wishbones it will be a little harsh for our roads, but I will be able to drive to meets etc... With regards to racing, my pockets are no where near deep enough nor is my talent frown

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 26th August 2012
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exupturbo said:
Do you know what CAM package is being used to generate the toolpaths ?
Not sure, all I know is he uses solid works for design and the CNC machine is a Hass.

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 26th August 2012
quotequote all
eliotrw said:
I didnt notice but were you using a c30-94 first and now a c38 series rotrex?
Yes it's a C38 wink

Edited by EX51GE R on Sunday 26th August 15:56

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 26th August 2012
quotequote all
Gorilla Boy said:
I think you'll have enough talent if you can merely drive it on normal roads briskly! thumbup

Lovely project, makes me wish i knew decent CNC machinists rather than normal machinists and that i could work more than just a turning lathe. tongue out
Thankyou smile it has been a godsend knowing Darren wink however if I'd never met him I'd be none the wiser and a bit richer !!

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 26th August 2012
quotequote all
eliotrw said:
Rotrexs are beyond awesome. I'M undecided as to which i will get for my 306 next april.
Its most likely to be a C30 as im not sure i need more than 250hp.
But i would love to fit one to an old bmw Mseries car of some description.
Been done and being done as we speak to m cars at TTS wink

EX51GE R

Original Poster:

1,394 posts

211 months

Monday 10th September 2012
quotequote all
Fuel system...











EX51GE R

Original Poster:

1,394 posts

211 months

Saturday 19th January 2013
quotequote all
Progress being made after work commitments from both Darren and I...







Need to pick up one of these when I'm in NY at the end of the month....


EX51GE R

Original Poster:

1,394 posts

211 months

Saturday 19th January 2013
quotequote all
chevronb37 said:
Any chance we can get my VHPD to give a reliable 500bhp? Can't be that difficult, surely?

This looks completely mega - love it.
Surely that's simple wink

EX51GE R

Original Poster:

1,394 posts

211 months

Sunday 10th February 2013
quotequote all
picked up an ATI super damper while in the US.....



and just in case you need to know what it is/does....

http://www.dragzine.com/tech-stories/why-torsional...

EX51GE R

Original Poster:

1,394 posts

211 months

Monday 8th April 2013
quotequote all
Fair bit of progress made over the weekend,despite Darren having to fit in a quick 10 hour rush job on the development R8 !!

We fitted the seats to the frames, fitted the S2 centre tunnel, removed rear speaker and stereo, fitted the ATI super damper ( of a job with the engine in!) fitted all the relevant cooling bits (oil, water& s/c) incl pipe work filled the gearbox with oil,bled the braking system.
All in all not a bad weekend, leaves Darren with about a days worth of electrical bits to do and then another full day of assembly for both of us, but then it's ready for the driveshafts to be run in on the rolling road slowly before mapping smile




One day..... wink


EX51GE R

Original Poster:

1,394 posts

211 months