Lotus Elise S1 to Motorsport replica conversion

[stratosboy]

started with this lovely S1 Elise:

and then these, wide arch S1 Exige body panels:


stripped everything out of Elise and sold that I didn't need - engine and box went to Switzerland!

Safety Devices roll cage ordered:


& fitted:


then a big suspension & brake refresh/upgrade:

all wishbones chemically cleaned and yellow zinc passivate coated, with 2 coats of clear PIR15 for extra protection
all new bushes & steering rack - new Nitron shocks


Front AP calipers onto rear, with Hi-Spek spot calipers:



AP Caparo 4 pot calipers on front:


larger bore master cylinder fitted:


wheels needed to be larger to fit wider arch clams - 50mm each side at rear and 20mm each side at front
so went with Braid (not the lightest, but look right (I think) - 17 x 8 front and 18 x 10 rear:

fitted with Toyo R888R tyres:

body work took ages to get right - many months work:



more to follow

[stratosboy]

Paul_M3 said:

Looks like a great project.

Don’t know what power it’ll have, but the brakes will definitely be up to the job!

engine is Audi 20v turbo. built for 500bhp, with large Garrett turbo, charge-cooler and LSD fitted to 6 speed box

[stratosboy]

so Engine is a VAG Audi AUG (large port head) with 6 speed O2M gearbox from a Seat Leon.
all rebuilt by JNL Racing, inc LSD going into gearbox:

new Audi TFSI crank - so effectively a stroker engine - 2.0l

with baffled sump:


modified inlet manifold and custom exhaust manifold



charge-cooler and uprated rad, inc. charge-cooler rad from Pro Alloy:



all fitted to car using custom mounts and uprated driveshafts:




more to follow

[stratosboy]

Caddyshack said:

Saw the finished car earlier, I am glad you did a thread....will be watching this one.

Great spec and looks lovely, I bet it is shockingly quick on track?

should be nippy!

[stratosboy]

whilst engine was away, bulkhead was prepared and larger Pro Alloy fuel tank fitted:



then soundproofed and heat shielded:



with oil, water and charge-cooler tanks fitted & Laminova


these pics gives some idea of difference between clams:



had always planned for car to be painted Porsche Miami Blue, I think it looks good,
great paint job by Anthony:



panel build up:



body re-build almost finished:



clams have since been removed for lights, wiring, mesh fitting:


ally panels are a quick release system to slide rear clam off rails bolted to longerons

whilst clam of, car went off for exhaust system fabrication and fitting - to ZK Engineering in North Yorks - great job:




this is about where I'm up to currently, not finished but should be for next spring.

[stratosboy]

interior will be improved too:
with Tillett seats and Scroth harnesses



a better range of Stack gauges as well as a GARW electronic dash:



new screen and a removeable tiny Momo steering wheel:

Edited by stratosboy on Sunday 10th November 20:14

Edited by stratosboy on Sunday 10th November 20:17

Edited by stratosboy on Sunday 10th November 20:20

[stratosboy]

Matt Cup said:

Looks great! What’s the inside of the clams painted with, is it some sort of bed liner?

yes very tough bed liner paint called ‘Raptor’

[stratosboy]

fitted lights, wiring and grills to both clams and got front clam back on for final time!

[stratosboy]

praise indeed, if you are, who I think you are...it's Porsche Miami Blue, it is a great colour.

[stratosboy]

cheers guys, will update with progress when there is some!.....not been on it much over the last month. Fitted new door locks over weekend, very fiddly and time consuming.

[stratosboy]

Yeah, ZK Fabrication is based in Selby North Yorks - phone Zak on 07817 597602

[stratosboy]

Can't afford to replace tyres on this very often, so gently does it, - need to keep traction as much as possible I think.

[stratosboy]

cheers Greg, I'll speak with my engine builder. I'm using a Maxx Sport ECU, which is programmable.

[stratosboy]

great pic, it is a fantastic colour isn't it? - looks ace!

[stratosboy]

cheers,
yes I'm not obsessed by top power figure, just want something that is quick and drives well. Would you recommend the place you had yours rolling road tested, looks fairly local if it's Cheshire.

[stratosboy]

Thank you, that's really helpful I'll make contact with him and arrange to book it in there when I'm ready, still got quite a bit to do yet.
Where abouts are you? I'd really appreciate a good look over your car to see how certain things have been done. I'm stuggling at the moment in trying to get my clutch slave cylinder connected up to Lotus braided hose.

[stratosboy]

I'm in Warrington

[stratosboy]

yes, thanks - felt it was too late to text last night 10.30 when I saw it. Will text you later - cheers Dave

[stratosboy]

cheers Lee, appreciate your endorsement about EFI, but doubt I’ll take your top spot!, just want it to be as driveable as possible

[stratosboy]

[quote=Peregrine Falcon]If may be worth looking into some subframe supports. They are known to flex and crack, mine has been strengthened, I will try and photo it. With you having wider rubber, the problem will be exaggerated.

Cheers this is useful to know - I'll look into this.
I have a brace across the back of the subframe to try to put some strength into it that way