We have a 6'6" client who loves his Elise so much that he is willing to go to great lengths to fit in both of his Elises (one street and one track). He is a fairly proportional gent so the challenge is both legroom and headroom. We have the headroom solved but the legs required more drastic measures.The pic to the left shows some of the modifications we made to an OEM pedal box that we bought. His originals remain untouched. We've initially found an additional 2" but he needs more. I think this will work for 90% of you who need additional legroom.
Sector111's Tasty Innovations Blog
Wednesday, May 1, 2024
Friday, April 12, 2024
Coolant Overflow
Lotus Elise 2ZZGE |
The Role of Coolant Overflow Bottles:
Coolant overflow bottles, also known as expansion tanks or reservoirs, collect excess coolant that expands due to heat during engine operation. As the engine heats up, coolant expands and flows into the overflow bottle, which helps to manage pressure buildup within the cooling system. Conversely, when the engine cools down, the coolant contracts, creating a vacuum that draws coolant back into the system from the overflow bottle, ensuring a consistent level of coolant and preventing air pockets within the system.
Degradation of Plastic Coolant Overflow Bottles:
note the plastic is fading |
Heat Exposure: Continuous exposure to high temperatures from the engine bay can cause the plastic material of coolant overflow bottles to degrade and become brittle over time. This deterioration compromises the structural integrity of the bottle, increasing the risk of cracks, leaks, and ultimately, coolant loss.
Mechanical Stress: Vibrations and mechanical stress within the engine bay, can exacerbate the degradation of plastic coolant overflow bottles. Over time, these mechanical forces can cause fatigue and microcracks in the plastic material, compromising its structural integrity and increasing the likelihood of leaks.
Signs of Degradation:
- The plastic will discolor (see pic below)
- The plastic is easy to scratch and may start to chip off
- The mounting tabs make break off
Implications of Degraded Coolant Overflow Bottles:
The degradation of plastic coolant overflow bottles can have negative implications for the performance, reliability, and safety. Some potential consequences include:
New bottle is on top |
Air Pockets: Leaks in the coolant overflow bottle can introduce air into the cooling system, disrupting the circulation of coolant and causing localized hotspots. Air pockets can impede the cooling process, leading to uneven temperature distribution and potential damage to engine components.
Addressing the Issue:
To mitigate the risks associated with degraded plastic coolant overflow bottles in Toyota 2ZZGE engines, we suggest you employ proactive measures:
Regular Inspection: Routine inspection of the coolant overflow bottle for signs of degradation, such as cracks, leaks, or brittleness, is essential. Visual inspection during routine maintenance checks can help detect early warning signs of deterioration and prevent potential issues.
Replacement: If signs of degradation are detected, prompt replacement of the coolant overflow bottle is recommended. Opting for high-quality OEM replacement parts made from durable materials can ensure long-term reliability and performance. They are still readily available from the Toyota Dealer and priced under $400.
Monday, March 25, 2024
Why Competitive Tunes Must Be Reflashed to Stock
If your ECU is tuned with a non-stock file, it will need to be reverted to stock. We have found that some competitive files use Euro tunes as their base. This causes several issues the least of which is our PG3's inability to read it.
If you have an ECU but don't know if it has been tuned previously, you can send it to us to read. Reading the file will reveal if it has been modified by others. See the attached image.
Once your ECU has a stock file in it, you can use our PG3 to read the file via your OBDII port. You will read the file and email it to us. We then modify it and send it back to you. You can then upload it into your ECU via the OBDII port.
The best aspect of our PG3 system is that you can flash back to stock at any time and revert your car without reliance on anyone else.
Tuesday, March 19, 2024
Engine Mount Degradation
Rubber automotive engine mounts play a crucial yet often overlooked role in sportscars. These mounts absorb engine vibrations, ensuring smooth operation and stability while driving at high speeds. However, as these mounts age and degrade, they can become a source of significant issues, impacting both performance and safety. In this blog, we delve into the intricacies of rubber automotive engine mounts in sportscars, especially the Elise and Exige, exploring their degradation process and the potential consequences.
Understanding Rubber Engine Mounts:
Rubber engine mounts serve as a buffer between the engine and the chassis, dampening vibrations generated during operation. In sportscars, where precision and performance are paramount, these mounts must withstand rigorous conditions, including high speeds, abrupt acceleration, and sharp cornering.
The 111 platform has the powertrain mounted transversely AND features a cable-actuated, manual, transmission. Under aggressive driving, powertrain movement is quite violent and can cause the shifter cables to perform poorly making finding a specific gear difficult. This naturally happens at the most inopportune times!
Factors Leading to Degradation:
Several factors contribute to the degradation of rubber automotive engine mounts in sportscars:
Heat Exposure: The engine compartment of sportscars often experiences elevated temperatures, leading to accelerated deterioration of rubber components. The 111 is mid-engined which can lead to hotter engine bay temps.
Vibration and Shock: Sportscars, especially those designed for racing, subject engine mounts to intense vibrations and shocks, hastening wear and tear.
Chemical Exposure: Exposure to oil, fuel, and other chemicals commonly found in the engine bay can degrade the rubber material of mounts over time. This is probably the smallest contributor to mount failure in the 111 platform.
Age: Like all rubber components, engine mounts undergo natural aging processes, becoming less resilient and prone to failure as they grow older.
Signs of Deterioration:
Identifying signs of rubber engine mount degradation is crucial for preventing potential issues. Common indicators include:
Increased Vibration: As mounts lose their damping capability, drivers may notice amplified engine vibrations, especially during acceleration or idling.
Excessive Engine Movement: Worn mounts fail to provide adequate support, allowing the engine to move excessively, potentially causing damage to surrounding components.
Clunking or Thumping Noises: Degraded mounts may produce audible noises, such as clunks or thumps, particularly when shifting gears or traversing uneven terrain.
Visible Wear: Inspection of engine mounts may reveal visible signs of wear, such as cracks, tears, or collapsed sections, indicating the need for replacement.
Consequences of Deteriorated Mounts:
The ramifications of deteriorated rubber automotive engine mounts in sportscars extend beyond mere discomfort. Some potential consequences include:
Decreased Performance: Engine mounts play a crucial role in maintaining optimal drivetrain alignment. Deteriorated mounts can compromise this alignment, leading to decreased performance and responsiveness.
Increased Wear on Components: Excessive engine movement resulting from worn mounts can lead to accelerated wear on adjacent components, such as exhaust systems, drivetrain components, and even the chassis itself.
Safety Hazards: In extreme cases, severely degraded mounts can compromise vehicle stability and control, posing safety hazards, especially during high-speed maneuvers or emergency situations.
Upgrade Options?
We identified performance problems early on with the 111 platform that were mount related. We started working on solutions many moons ago: HERE. As a result, we developed three levels of mount upgrades based on the desired performance - with corresponding trade-offs. The biggest tradeoff is the added vibrations from mounts.This solution replaces two mounts, front and rear with new mounts with stiffer bushings. The NVH penalty with this kit is not acceptable for a car run on the street most of the time. As a result, we consider this a 20/80 solution - Street/Track. It is really for cars that are driven on the street, just to get it to the track.
This is a Race solution for cars that are trailered to the track. It provides the best powertrain rigidity but the biggest NVH penalty. We consider this a 100/0 solution!
Conclusion:
We are seeing mounts on the 111 platform that are starting to age. We're hearing from clients who are having more shifting related issues. This only makes sense as these cars were introduced back in 2005! The various solutions we offer can help improve performance but also extend the life of existing mounts.
Regular inspection and timely replacement of worn mounts can mitigate potential issues, ensuring that these high-performance vehicles continue to deliver thrills on the road or track. We don't consider that these parts as consummable bits, but in reality, they will wear out.
Thursday, February 29, 2024
Baffled Fuel Tank for Lotus Elise & Exige
We landed on a design that uses a large tube to reduce fuel starvation. This design keeps the fuel in the pump side of the tank and prevents fuel sloshing back and forth. We're very happy with the design and have been running it in our 111RS for almost a year.
Of course we started with a design that we were sure would work but failed because it conflicted with the float. Our new design fixes that issue and works as expected.Our first design |
Monday, February 19, 2024
Crazy Ideas: Tubular Doors!
Back in 2005 we had this crazy idea to make the Elise even more raw. Tubular doors are a thing for Jeeps and the thought to make one for the Elise got us dreaming...lucky for us we worked with an Engineer who was also a master fabricator. He came up with this idea.
Monday, January 29, 2024
DOT Windshields and the Purpose of the 'Frit'
One crucial automotive component often overlooked is the windshield. While developing our 111glass, we learned some new facts about this product. For those of you who love learning more, this Blog aims to discuss two arcane details: Safety Glass Vs Tempered and the Frit.
Safety Glass does not shatter into a 1000 pieces! |
The Evolution of Safety Glass:
Departing from the fragility of early tempered windshields, modern windshields embrace laminated safety glass construction. This actually became a requirement for cars in the US in 1937. Comprising a layer of polyvinyl butyral (PVB) sandwiched between two layers of glass, it ensures enhanced safety in the event of breakage as shown in the above image.
1000s of pieces of Tempered glass |
DOT Glass Standards and Homologation:
The 111glass adheres to the Department of Transportation (DOT) standards, meeting stringent guidelines for thickness and durability. Produced by a North American OE windshield supplier, it is homologated to comply with both North American, UK and European safety requirements. Correct DOT markings are incorporated, ensuring seamless adherence to local inspection standards.
Optics play a crucial role in choosing safety glass as it provides superior visibility without compromising clarity, far surpassing the performance of Lexan race windshields. Our original ArtCar had a Lexan windshield as did 111RS002 - until we changed it to glass. Foggy Lexan on the preresto 111RS002
Lexan is great on a race car but the optics for the street are subpar with fogging and scratching challenges that will frustrate the normal street driver.
The Frit: The What & The Why
Beyond safety, the 111glass incorporates Frits. What is a Frit? It is the black dots that you see on the edges on the windshield.
The term "frit" refers to the enamel band applied around the periphery of the windshield. This enamel, essentially composed of glass ground into a fine powder and mixed with various pigments and additives, is applied to the glass in a paste form through a silk-screening process. Subsequently, the glass undergoes heating in a furnace, causing the frit to meld with the surface, establishing a permanent bond.
Our '111' is actually sandwiched within the glass along with the Frit.
What does the Frit do?
1. Promotes Adhesion
The most important aspect of the Frit to enhance adhesion with the glue that holds the windshield to the frame.
2. UV Protection
The Frit covers the adhesive that is used and reduces degradation that comes from UV exposure.
3. Cosmetic Transition
The black dots create a smooth transition from the black to clear portions of the windshield. This helps to ease the eyes and makes for a more attractive installation.
4. Distortion Reduction
Some windshields, including the Elise, have significant curvature that can cause distortion during the manufacturing process. The Frit helps to reduce this visually by hiding it.
Thursday, January 18, 2024
2ZZGE Water Pump Failures
We are starting to notice that more water pumps are failing on the 2ZZGEs. We are finding even cars with low miles are starting to see this issue.
If you are noticing that your coolant bottle level is dropping, have a look at the weep hole on the pump, as shown below. The white/pink residue collecting on the housing is an easy way to note that the pump is giving up!
Toyota water pumps are available. Be sure to get one with the plastic impeller blades.
another leaky pump |
Tuesday, January 2, 2024
2023 Summary & 2024 Projections
snuck in a 111glass here... |
Another year passes as we continue to make advances! Honestly, it has been a tough year but your support and some good ole 'nose-to-grindstone' has made 2023 a decent one. We grew ever so slightly but it certainly took some 'small business hustle' to get it done! A grey recessionary cloud has been over our heads for the last few years, leaving us somewhat nervous - but we're now slowly, but surely, finding the courage to invest in the future. I've summarized some of our achievements below and wrap up with projections for 2024 and onwards. We continue to build this company to support the 111 platform and grow further to become the go-to shop for niche and supercars of all types in the Temecula Valley.PartsWe introduced 11 new products or production derivations in 2023. We launched a couple of big items, a few medium items and a few small easy to do bits as well. The shiftR111 2.0, 111glass and RS343 were probably our biggest new products. The DOT glass windshield required a huge tooling investment that will take years to pay off but we are glad we made the leap to ensure you have access to a critically important component. The RS343 turned out even better than we thought! Our Tcable fixes an ever increasing issue that is plaguing earlier cars with higher miles. The LEDkit is another tasty bit that makes these cars fun to drive at night - fixing those woeful stock lights. We reissued the subSTIFFY2 and created a Special Edition ETHOS wheel. Our Emira Decat landed before the actual car - at least in North America!
Driving the Tail of the Dragon was a hoot! |
R&D
We completed the tune for the KATANA3 and have been really happy with how it is running. Kits are shipping in early Jan. A related development is advances we have made with tuning the ECU. Our partner, Brent@Xclusive Tuning has advanced our abilities to the point that we believe we are the leaders in our control and understanding of these ECUs. We continue to learn more and will be attempting CARB certification for the KATANA3 this year. The Evora Stage II tune that we developed showed a 40hp bump and promises even more. A couple of new Nitron innovations are coming. We have been testing a new 46mm Single on our 111RS and will release it this year. Their Emira solutions are also coming together.We serviced over 100 cars in 2023. Cars from all over the country have been sent to us for work. At the time of this writing, we have cars from CA, TX, OR, GA and SD. We're proud to work on these cars and flattered that owners are willing to send their cars across the country to get our form of TLC. We want to see these modern Lotus on the roads for decades to come and continue to invest in our service capabilities to ensure we can meet your needs. To that end, we've added another excellent technician who hails from Ferrari of SanDiego. Jorge joins Carlos to give us a team that can service sportscars of all types.
Collision
We repaired a dozen cars in 2023 that needed collision work. Keeping these cars on the road is important to us. Bringing a few back from being totalled warms our enthusiast hearts!
111RS #002 |
We finished another 111RS and started two more builds in 2023. These cars are getting real attention from drivers looking for a pure driving experience. Our comprehensive upgrades enhance the cars and are winning over many owners. As we find new improvements, we have been incorporating them into each build.
Equally important is that we restarted production of our Drakan Spyder. We had secured all the remaining IP that we did not own, during COVID, but it took until last year for us to gather the resources to restart production. Cars #8 & 9 are in build. Supply chain challenges remain the biggest hurdle as we discover certain parts are no longer available - the steering rack has confounded us much of 2023 but we have a solution in the works. We plan to build up to 6 more this year if the Lightweight Gods remain smiling...
Drakan #9 |
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