500bhp lotus S1 Exige build...
Discussion
My S1 exige was Honda'd at Phoenix motorsport in early 2008, very happy with the N/A until i met Darren Cudd while i was doing some work for Omex performance electronics, he suggested a Rotrex...
after a few TD's with an intercooler we decided a charge cooler was the way forward...
Again, very happy with the performance, Darren then up sticks and moves to silverstone to work for TTS, we then decide to up the boost and change the cams, however after discussion we decide screw it! sleeve the block, 2.2L stroker kit, uprated rods pistons etc....
Oh yes and bigger blower, a MUCH bigger blower...
Now to take the extra power i have decided to swap all the wishbones to S2 K series items and run the uprights with the S2 bearing packs...
Powder coated and new balljoints C/W JSR rosejoints...
2 pots on the rear too...
A job we have been discussing for a while is to make some Ally uprights, so darren has been busy in 3D solidworks...
Bracket for the new S/C...
I'm sure once i point Darren to this thread he can update as he goes too....
Marc.
after a few TD's with an intercooler we decided a charge cooler was the way forward...
Again, very happy with the performance, Darren then up sticks and moves to silverstone to work for TTS, we then decide to up the boost and change the cams, however after discussion we decide screw it! sleeve the block, 2.2L stroker kit, uprated rods pistons etc....
Oh yes and bigger blower, a MUCH bigger blower...
Now to take the extra power i have decided to swap all the wishbones to S2 K series items and run the uprights with the S2 bearing packs...
Powder coated and new balljoints C/W JSR rosejoints...
2 pots on the rear too...
A job we have been discussing for a while is to make some Ally uprights, so darren has been busy in 3D solidworks...
Bracket for the new S/C...
I'm sure once i point Darren to this thread he can update as he goes too....
Marc.
Sorry for the lack of updates, but we are waiting on parts really, rear uprights are still in the planning stage...
waiting on spot calipers from hi spec, but they have a two week lead time
and the engine block is off being stripped. I'm sure once all parts are in place things will happen faster 
waiting on spot calipers from hi spec, but they have a two week lead time
and the engine block is off being stripped. I'm sure once all parts are in place things will happen faster Ok, looks like darren has finalised the front uprights...
"redesigned the front uprights today to sort out the lower ball joint issue. have done it as a seperate bolt in plinth so that it can be dissasembled and the taper can be removed off the car in a press ect.
i did in the end decided to do the plinth in alloy not steel, its strength is fine as it will all be machined in aircraft spec alloy anyway."
"redesigned the front uprights today to sort out the lower ball joint issue. have done it as a seperate bolt in plinth so that it can be dissasembled and the taper can be removed off the car in a press ect.
i did in the end decided to do the plinth in alloy not steel, its strength is fine as it will all be machined in aircraft spec alloy anyway."
andygtt said:
fantastic quote.
love the project... whats the target weight with all the upgraded stuff, is the brakes and wheels changing in size at all? whats the torque and rev target?
Torque should be somewhere around 350-375 ftlb, will be revving to 7800-8000 rpm.love the project... whats the target weight with all the upgraded stuff, is the brakes and wheels changing in size at all? whats the torque and rev target?
With regards, to weight not sure really, I'm guessing a STD S1 exige weighs around 775kg we've stripped out a bit but added in some as well, although the wheels are a fair bit lighter and the ally bits will save some, so I'll take a stab at 800kg dead.
engine came back from vapour blasting today.
back on the cnc to drill out the head bolts for larger items (would have done this the last time it was on the machine but we had to have a roll tap ordered up as there wasnt one off the shelf)
then down to the fab shop, block heated up, o-rings fitted, plenty of extra special sealer as i dont trust just the o-rings, and the liners are dropped into place
then the jig tophats are placed into the bores and the whole lot is clamped down hella tight!
will leave this to go off over night, then it will come off, go back on the machine for block facing, it will have its deck plate fitted and have its final bore and hone.
back on the cnc to drill out the head bolts for larger items (would have done this the last time it was on the machine but we had to have a roll tap ordered up as there wasnt one off the shelf)
then down to the fab shop, block heated up, o-rings fitted, plenty of extra special sealer as i dont trust just the o-rings, and the liners are dropped into place
then the jig tophats are placed into the bores and the whole lot is clamped down hella tight!
will leave this to go off over night, then it will come off, go back on the machine for block facing, it will have its deck plate fitted and have its final bore and hone.
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...EPIC work never the less!
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 +
Chris Peacock said:
Heard that the rotrex gives no "whine"... Unlike a jrsc?....
Great build btw....
Yes, no whine...Great build btw....
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
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