Project Rexige... Lotus S2, K24 Turbo + sequential project

[sl0wlane]

A year in the making so far, most parts ready to go in... bit more welding to do...

[sl0wlane]

We get closer





Quaife sequential box dropped to HPE on Saturday for a cosmetic spruce up (internals are looking all good) and Dan has my engine block and components "next in the queue"

[sl0wlane]

Butter Face said:

I'd say more like 500!

Yep, around about, I'll be happy with 5**, I met a chap with a K24, exact same turbo in an aerodeck (I think)... 608bhp and starting to get on boost at 2.5k... that will be lovely if we can close to that.

[sl0wlane]

A bit of detail on the spec (so far):

Fully built and Darton lined K24 Block
K20 head - 3 angle seats, mild porting
Inconel exhaust valves, Clockwise motion "bee hive" springs
Clockwise motion "turbo" cams with adjustable exhaust pulley
CP 9.5:1 forged pistons and Clockwise motion forged rods - tool steel wrist pins
Water pump delete (BMW electric pump) - smaller alternator
Jenvey "Turbo" twin plenum / inlet manifold - 70mm J37 TB
ID1000 injectors, Clockwise billet rail
DW fuel pump and fuel regulator

Custom built Inconel equal length tubular manifold
Custom built roof mounted intercooler

Owen Developments ODGT3579HTA m-spec Turbo, Tial exhaust housing
Tial MVR 44mm wastegate
3.5" turbo back exhaust
Wastegate v-band to allow either through silencer or "screamer" option

Quaife 5 speed sequential with Quaife LSD ("race" ratios)

Quartermaster ceremetalic clutch
Clockwise lightweight flywheel

Efi Euro 4 ECU
HP Electronik PDM
Aim MXS dash

Comments and suggestions welcome

Edited by sl0wlane on Thursday 5th October 08:08

Edited by sl0wlane on Friday 6th October 18:47

[sl0wlane]

Silencer now on mount:


The projects namesake (my boy Rex), checking the driving position (by the time I finish this thing he will probably be able to drive it!):

[sl0wlane]

Umm... I guess nothing more than having a turbo obsession and a taste for cars that are inherently flawed and hard to drive?

Aiming for ~850kg and 5##bhp... so yes, a bit more than 500bhp per metric ton.

[sl0wlane]

TheDrBrian said:

Are you not afraid you might of ruined it?

Nothing against the standard of work more that you've taken a car that has a nice balance of power, grip ,weight and you've massively skewed that triangle towards power.

Ruined? Hmmm... I would say it is "changed dramatically".. it's not really an Elise anymore, but I bought the car with this outcome in mind from the outset... so it will be what it will be... which will probably be quite scary

There are a few 111 based cars running this kind of power and more, not least of which is Ronin's RS211, which I have had the pleasure of riding around the canyons in (EPIC!)... Jamie Wilsons Time attack car... and a fair few more (not to mention the Hennessey venom GT which has over 1000bhp and still same chassis albeit extended).. the chassis can take a LOT more power than the 156bhp it left the factory with.

I have upgraded the other areas, and I probably will readdresses these again later once it's running... it has 4 pots, nitrons, spherical bearings, wider rubber etc.

The aero will of course be addressed and I have MY2010 Exige parts ready to fit (the car started out as a 2005 111S Rover engine Elise)... the roof will have to have quite a big scoop for the intercooler too... I'll deal with that bit once it's running and mapped.

Edited by sl0wlane on Thursday 5th October 11:33

Edited by sl0wlane on Thursday 5th October 11:35

Edited by sl0wlane on Thursday 5th October 11:38

[sl0wlane]

Fabrication all done... next phase, build up engine, clean gearbox casing, make a loom... and map

[sl0wlane]

Well... progresss has been slower than I would like... but the engine and box I am assured will be ready by the end of this month...

New longerons, more gold sticky back plastic, new subframe... Aim dash mounted, fire systems, new battery cable and battery moved to the front, heater deleted... a fair amount done... just need an engine, gearbox, plumbing, loom and mapping now (just)...

[sl0wlane]

Full spec:

K24 block
K24 crank
Darton MID sleeves (block is 99x87)
K20 oil pump and balance shaft delete
Clockwise motion sump baffle
K20a2 head
3 angle valve seats
Inconel exhaust valves, stainless inlet valves (exhaust valves slightly larger)
Exhaust ports have a light flow job
BC stage 2 turbo cams
Adjustable exhaust pulley
Saenz rods
CP 9.5:1 pistons
All componants fully balanced

Jenvey “turbo” inlet manifold 70mm throttle
Honda J37 electronic throttlebody
ID1000 injectors
DW320 Pump
DWFPR1000 fuel pressure regulator
UK 99RON fuel (93 USA MON)

Equal length Inconel exhaust manifold, 23” primaries, with wastegate priority
44mm TiAL MVR wastegate
Owen Developments ODGT3579HTA m-spec turbo, TiAL v-band exhaust housing
MAC 4-port boost solenoid
Roof mounted (because mid-engine) custom air-air intercooler
3.5” turbo back exhaust - no cat

Emtron KV8 ECU with loads of sensors:
Fuel pressure
Fuel temperature
Exhaust manifold pressure
Exhaust manifold temperature
Wideband Bosch knock
Wideband LSU4.9 lambda
Pre and post throttle pressure sensors
Etc etc

Anyone want to guess what power it might make?

[sl0wlane]

Getting closer... almost time to fire it up for the first time, both exciting and totally nerve racking.

I’m almost glad I’m in another country and cant be near it for first start up, brand new never been run engine adds an element of (wallet) fear to the mix.

Yep... I think the numbers here are about right, I’ll be gutted if if doesn’t make 500+ at the wheels, power graph to follow in the not too distant future (I hope!)

[sl0wlane]

Many things have happened since I last updated this thread.

Engine is running, had a bit of fun and games with the gearbox, but mostly just learning how to set them up really...

https://youtu.be/uCmArHv8I8E

All now working.





I have a list longer than my arm of stuff to finish configuring on the dash/wheel/PDM/ECU...

[sl0wlane]

https://youtu.be/si28-VpWwAM

[sl0wlane]

Only managed 7k @ 18psi and a very conservative map so far, needs another day on the rollers to get the headline result... So has only done 420 at the wheels so far.