Break-in, Testing & Failure: KATANA3, shiftR 2.0 & More

 

Testing continues with various new parts we plan to introduce.  We had some wins and one failure.  Running parts on our cars first is our mantra so our clients are getting the best experience.  Though this has not been 100% successful, it has kept us in good stead.

Let's start with the failure - new fuel pump.  Last year, we had trouble sourcing a Denso pump that we had been selling for years on cars making 300hp.  We decided to test out a new pump, from another OEM supplier, Delphi.  This pump was fitted to our last Outlaw and run for nearly a year, on the road and track.  It ran in our Outlaw that we ran up Palomar Mtn Hill Climb last year.  We transferred it to our latest 111RS to continue racking up miles.  Unfortunately it failed almost immediately.  But the 'failure' snuck up on us.  The car ran fine under 6000rpms - which is where we were running it for a 100 miles or so while we broke in our newly built Mountune engine.  Once we started dipping into the second cam, the car would hesitate.  We data logged and saw the AFRs going lean.  It took us a bit to get it figured out but swapping in a stock pump solved our problem.  The funny thing is that the Delphi pump is actually made by Denso.

The KATANA3 on our car is running great.  I hammmered the car up and down the mountain and our back canyon roads.  Our Calibrator, Brent, is coming in a couple of weeks to do some final tuning.  We will get it onto a dyno then and see how she is doing.  The engine still has less than 500 miles on it and it would be ideal if she had over 2000 miles before the dyno.  That is not likely this time so we will probably dyno her again later this Summer.

I'm digging the all silver colorway- with the cherry on top!

The shiftR111 2.0 version that has been in my car is doing fine.  We made a couple of tweaks as there was spring related issue that we had noticed and the reverse lock-out.  As it turns out, we were able to sort out the lock-out with shifter cable adjustments.  The spring issue was related to us not torquing the CG mechanism fully.  Sorted.

So far I don't feel any negatives with this kit.  The overall feel is better especially since the reverse lock-out works super smoothly.  This is a HUGE improvement over our previous version but tempered by the fact that you really don't use it that much.  Regardless, it now works better and each time you select Reverse, you will do it smoothly.  Shifting into each of the gears feels as good as with our original, if not marginally better.  The bearing design is technically superior so it should feel better...

Chillin' at the RSF Cars & Coffee

I am running a set of Nitron 46mm Singles on this car with softer springs than we used to run.  The car feels really good but we can make it even better.  I think we will call our man Dave T in for some Ride & Handling work.  Especially with Nitron setting up their North American operations here in town, we will be able to develop a kit suited to our over rough canyons.  

This car is also running the OS Giken LSD.  What an awesome bit of kit!  We introduced these back in 2010 and they have been favored by all the fastest guys.  It still amazes me how it allows you to put the power down sooner - especially on our bumpy roads.  This is really a must have for any pushing their Lotus hard - especially if you are about to get your gearbox rebuilt.

111RS #3 Build: Suspension, Brakes & More

We are starting to bolt on all the four corners of the 111RS now.  This includes the Refreshed Wishbones with MONOballs and Refreshed Uprights with new Hub Bearings.  New hardware is getting installed as the old bits are looking tired.  We added new 12.9 hardware to the refreshed calipers as well.  FASTarms are also a must have for this build.

This build is getting the DNA Front & Rear Swaybar kit as we've become big fans.  We love the ability to run much softer spring rates thanks to roll stiffness being managed by the sways.  The added compliance on rough roads and tracks is remarkable.  We will install the DNA Rear Toe link brace as well.  This is the first 111RS that has received this upgrade - it almost feels sacrilegious considering we make excellent braces ourselves!

We had a set of Nitron 46mm Singles that we had rebuilt sitting on our shelves.  We also have 350# and 500# springs that are reasonably light.  Usually we go lighter still with the DNA sways but we would test these rates on this car.  Generally we had run Nitrons in the past with 450# spring and up.  The lighter rates that we are running compare with what came on their Street Series dampers.  Since Nitron are building a Tech Center in our town, we thought it would be good to have a set on this car to test and tweak.  If you have not seen our video interviewing the Owner of Nitron, Guy Evans, please watch it: HERE

ULTRAdiscs are simply the best rotors for these cars with a 10lb unsprung weight savings.  We have paired them with G-loc R10 pads.  I like my cars to brake more aggressively than stock and this combo does not disappoint.  They are killer in the canyons and work fine on track.  Our QWKbleed lines are being fitted.  BULLETstuds were added as well.

We've deleted the passenger oil cooler - of course!

111RS #3 Build: Rad/AC/HVAC Reinstall

End caps are grey!

 This 111RS is getting ProAlloy's proRAD Triple Pass as the stock radiator was looking old and grey.  The plastic end caps had changed from black to grey in color.  These end caps are known to crack and then leak.  We change the radiator out on all the 111RS builds as a preventative measure.  This color change is easy to see from the outside of the car so something we suggest should be inspected.

We also installed ProAlloy's AC Condenser.  The AC hard lines to the stock condensers often rip the threads off the fitting upon removal.  It happened to this car so we had the lines repaired and replaced the condenser with a new rad.  Carlos cleaned up the stock fans and remounted each of these parts into their stack.  

The HVAC unit was cleaned up.  We took the opportunity to add some insulation to the inside of the unit to see if we can improve the AC performance.  We've not tried this before so it will be interesting to see the affect.

Lee cleaned up the radiator shroud and crash structure as everything was apart.  It all looks great now and reinstalled.

111RS #3 Build: Powertrain Out

 We pulled the rear clam off the car and yanked the powertrain.  It can be telling what a car has experienced when it comes apart.  There will be tell tale signs of various 'experiences'.  This car shows no hidden crash damage or repairs but it has seen some dirt.  There is dust build up that suggest silt from driving through a deep puddle.  The car came to us running fine and we will completely clean and replace any thing that may have been submerged.  

The above image shows some dirt build up that seems water related.  

The engine/trans will be full rebuilt along with new suspension, brakes, etc.  The engine has leaks from a couple of locations but will get rebuilt anyhow.  It will be given a new lease on life once the boys at Mountune are finished.  The clutch was in great shape with plenty of life.  Regardless, we will replace it with new and keep this as a spare.  The gearbox is getting rebuilt and will received the OS Giken LSD.  

We plan to paint the subframe black so Lee cleaned it up before we hit it with high temp paint.  It was is much better shape than many we have seen before it.  No signs of crash damage.  The bottom of the chassis is in good shape with minimal signs of damage.  The bottoms are very vulnerable on these cars and usually scars from road debris or off-road excursions are easy to spot.

KATANA3 Developments

 We have been running with the KATANA3 kit on our 111RS test mule for the last couple of months.  Brent, our calibrator, has been out for the last couple of weeks fine tuning.  It is running nicely so we decided to run it at the Palomar HillClimb that was organize during this years West Coast Lotus Meet.  

This video is me Running Up That Hill...

We were the headline sponsor of the event and provided support from our team to make the event a great success.  It made for a very long day (starting at 3:30am!) but it was a fun event and the first time it had ever been run.

Cars lined up after running up the Hill

Brent and I paid a visit to SEMA to meet their emissions lab personnel.  We toured their facility and came away fully impressed with their support to the aftermarket.  We have also engaged a small company with engineers who assist companies like ours with the CARB process.  They offer full testing so we are even more committed to chase the EO# that would really help our KATANA3 product.

One thing we learned is that getting a KATANA3 upgrade for K1 or K2 owners is possible in this application.  Based on how well the K3 is running, we are certain several client will want to upgrade.

111RS Powertrain install

 We are getting very close to firing up the 111RS.  We installed a Exedy clutch and Fidanza flywheel on her.  The Mountune engine and rebuilt gearbox are going to need some break-in miles.  

When you are building a car that is utilizing some existing parts, you end up discovering issues during the reassembly.  In some cases, we simply replace them with new bits and in other cases, we clean them up and reuse.  The alternator is a perfect example of an item that was working on the car but looked a bit tired.  We decided to send it out for a rebuild and upgrade.  

Rene and Carlos have tag teamed this build so we can get her done sooner.  I'm grateful to have two very experienced and capable Primary Care Technicians putting their TLC into this 111RS!

HOTplate install was a prerequisite for this 90/10 street/track car.  It is clear to me that these cars suffer from over oil cooling.  The HOTplate has been a great solution to get the oil up to temp sooner.