Baffled Fuel Tank for Lotus Elise & Exige

 Fuel starvation is a real problem on the Lotus Elise and Exige.  Our V2fuel tank has been a great solution for many clients to fix this issue.  It sadly went out of production so we started working on an alternative idea, the 111tank.  

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

There are two types of Federal (North America) tanks, ones for '05 cars and a different design for '06 and later cars.  We have sorted our design for each variety.  Our 111tank takes factory tanks, opens then up, removes the old baffle and we insert our design.  We then reweld the end cap and pressure test overnight to make sure she is sealed.

The factory tanks have plumbing related to emissions and safety.  We don't interfere with any of these features allowing you to have a tank that is as safe as stock but with NO fuel starvation.

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.

It was fixed and did not open.  You needed to step over it.  We had to relocated the side view mirror and the lovely Elise door hinge was removed.  Ultimately we did not commercialize it but we did have some fun driving around without a door!  

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

Tempered glass on the other hand was originally used on windshields. This glass will shatter into many small pieces and is therefore not a great product for windshields. It is still used on side 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.

Foggy Lexan on the preresto 111RS002

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.

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.

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

Seals may be failing due to lack of driving!  Of course, cars with higher mileage will benefit from a proactive swap.  If you car is over 75k miles, I would budget for a service.

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.

Parts

We 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.

Service

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

Cars

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

Another new project that we've managed in 2023 is selling an ICE to EV conversion for a Jag XKE.  We partnered with Electrogenic to offer their bolt-in solutions for several classic cars.  I believe there is a market for these products as most people are getting accustomed to the ease and reliability of EVs vs ICE - especially in old cars that often sit broken.  These conversions are breathing new life into cars that have otherwise been languishing unused.

Events

We hosted or attended over 10 events in 2023 not including the cars & coffee events!  From Miami, to TN to Detroit to Fremont along with England and more.  It was great to meet up with many of you and see your cars.  One of my great joys with this business is getting to hang out with like-minded car folks.  The Tech Seminar we hosted with Brent was our first where we allowed clients to attend on-line.  Expect more of these in 2024.

  

2024 Projections

We will be doing more of the same in 2024 that we accomplished in 2023.  

We are shooting to deliver 3-6 111RS in '24 and 6 Drakans.  EV conversions are in our gun sights with one already booked in for Feb.   We will expand our Service offerings into more sports cars with the goal of becoming the best shop for supercar service in the Temecula Valley.  

I plan to travel as much, maybe more, to see many of you.  LOG will be in Austin this year and we will be there with a 111RS.  I'm sure another trip to England will happen along with a much overdue trip to Japan.  A trip to Canada is possible along with my hometown, Detroit.  West Coast Lotus Meet will be held so a NorCal trip is guaranteed.  At least two Tech Seminars and a new HQ Warming Party (see below) are planned along with a Track Day or two and possibly a Wine Run.

We've identified several products that we plan to develop and introduce in 2024.  Our goal to keep the 111 cars on the road helps focus what parts we work on.  Expect some sexy items and a few more mundane items.  Emira parts are high on the list as they begin deliveries.  We sold our first tasty bit in 2004 - 20yrs ago!

The biggest recent development is that we should be in a building of our own.  We have found a building and opened escrow in Dec '23.  We will share it with my other company, Brand Assassins, as they need space as well.  Assuming the SBA loan process goes smoothly, we should be holding keys in March!

Needless to say, 2024 is going to be a fun year.  Delivering high quality parts and service remains our key mission and we appreciate all of you who continue to support us!  

Windshield Replacement

 Now that we have our own OEM-style glass windshield, 111glass, we have been getting many requests about the installation.  Here is the basic sequence of events to get the job done.  We use a local installer and suggest that you use a professional - this is really not a DIY job.

Unlike some speculation, the front clam does NOT need to be removed to replace the windshield on these cars.

The hardtop/softop needs to be removed along with the access panels at the base of the windshield.

Remember the windshield is not a structural member and will crack if you put your weight onto it.

Apply heat to remove the factory rear view mirror puck.  Note how he uses pliers to hold the puck.  Of course the mirror should be removed first.

Our installers separate the old glass from the frame using a special tool.

Glass is removed and new adhesive is applied

Suction cups to hold the 111glass and position into place - yes, it takes two people

Be careful and slide the glass under the clam as shown above

Let the adhesive set for 3-4hrs before driving

Most installers can get the replacement done in about 2 hrs.

The 111glass shown above is our Street version.  The Race version is shown below - the only difference is the location of the '111' icon.  On the Street, it is on the Passenger side and on the Race, it is in the center bottom.

Wheel Bolt Stud Replacement Frequencies in Track-Driven Cars

With high-performance driving, every component of a vehicle plays a crucial role in ensuring optimal performance and safety. One often overlooked but critical element is the wheel bolt stud. These seemingly small components bear the brunt of intense forces and stresses, especially in track-driven cars. In this technical blog article, we delve into changing wheel bolt studs and why it matters for enthusiasts pushing their vehicles to the limit.

Understanding the Basics

Wheel bolt studs are the unsung heroes that keep your wheels securely fastened to the hub. In a track-driven car, these studs are subjected to extreme loads, including lateral forces during aggressive cornering, intense braking forces, and acceleration stresses. Over time, these repeated dynamic loads can lead to fatigue and, ultimately, failure of the wheel bolt studs.

The Importance of Regular Inspections

Ensuring the safety and reliability of your track-driven car requires a proactive approach to maintenance. Regular inspections of the wheel bolt studs should be a standard part of your routine. Look out for signs of wear, such as elongation of the stud holes, corrosion, or visible stress marks. Detecting these issues early can prevent catastrophic failures on the track, where the consequences are amplified.

Factors Influencing Wheel Bolt Stud Wear

Several factors contribute to the wear and tear of wheel bolt studs in track-driven cars:

Driving Style:

Aggressive driving, particularly frequent hard acceleration, braking, and cornering, puts additional strain on wheel bolt studs.

Track Conditions:

The type of track surface, variations in elevation, and the overall condition of the track can impact the stress on wheel bolt studs.

Wheel and Tire Configurations:

Larger and heavier wheels, as well as wider tires, can increase the load on the wheel bolt studs. Properly torqueing lug nuts and using the correct stud length for your setup are crucial.

Material and Design:

The material composition and design of the wheel bolt studs play a pivotal role in their durability. High-quality materials and designs that distribute stress evenly can enhance the lifespan of these components.

Our HEXstuds and BULLETstuds have been great solutions used on track Elises/Exiges since 2006.  We've had great success with them but even they can fail if misused or ignored. 

 Determining Replacement Frequencies

While there is no one-size-fits-all answer to how often wheel bolt studs should be replaced, several guidelines can help inform your decision:

Manufacturer Recommendations:

Refer to your vehicle and wheel component manufacturers' guidelines for recommended inspection and replacement intervals.  Do NOT over torque!

Inspection Results:

If visual inspections reveal signs of wear or stress, it's advisable to replace the wheel bolt studs promptly.

Usage Patterns:

Track enthusiasts who frequently push their cars to the limit may need to replace wheel bolt studs more frequently than casual drivers.

In the pursuit of optimal performance on the track, we sometimes forget about safety. The often-overlooked wheel bolt studs are integral to the safety and reliability of your vehicle. By understanding the factors that contribute to wear and implementing regular inspections, track-driven car enthusiasts can ensure that their wheel bolt studs are up to the challenge. The frequency of replacement may vary, but the commitment to proactive maintenance is non-negotiable for those of us who seek the thrill of high-performance driving without compromising safety.

111RS006 Build: Introduction to a Special Tribute

 We were approached by a client to refresh his '06 Exige which we were happy to do.  He sent the car to us from across the country with the intention of doing some basic upgrades and some bodywork.  After we reviewed the suggested work, he told me that he would be interested in turning the car into a 111RS.  Then he told me the full story.

This client wanted to build this car as a tribute to his brother, fallen Naval Special Warfare member John Douangdara, who along with his MWD Bart and 29 other Special Operations service members, were tragically lost in Afghanistan on August 6, 2011. He belonged to Seal Team 6 and the elite Gold Squadron of DEVGRU.

John was an Elise owner who loved his car.  He was a true driving enthusiast.  Most of his friends drove bigger, more powerful cars, but John preferred his Lotus.  I think we all can relate to this sentiment!

We plan to build a very special 111RS to honor John.  This black Exige will sport the Type 72 color scheme.  We will add some special touches that we hope will make this build even more meaningful for John's family and friends.  We plan to recruit our suppliers to make this a truly special car.  Nitron are already on board!

Drive Defensively, Think Like a Motorcyclist!

We get calls weekly from clients that have been in an accident.  Though we provide Collision work on cars, we would rather you not need this service!  This article has been written to provide tips that may help you avoid having to make that dreaded call to us.

 Driving is why we buy these lightweight cars.  However, these exhilarating drives often come with a caveat — visibility. The low profile of cars like the Lotus or Alfa or BAC or Drakan, can be a challenge when surrounded by towering SUVs and Cossovers.

Motorcyclists, with their even smaller profile on the road, have long developed a series of defensive tactics to ensure they're seen and safe. I bought my first motorcycle way back in 1990 and have been using these tactics since then.  

1. Assume You're Invisible

As many motorcyclists will tell you, always assume other drivers can't see you. Adopting this mindset ensures you're always prepared for sudden movements by other vehicles. Stay vigilant, be proactive, and always anticipate the next possible move by drivers around you.

2. Optimal Lane Positioning

Riders often shift within their lane to ensure they're in the driver's line of sight, especially at intersections. As a Lotus driver, choose your lane position wisely. The goal? Always be where you can be seen, and more importantly, where you can see others.  At intersections, especially when stopped, I like to position myself so I can see the car's driver side side mirror clearly - and hopefully they see me.  We have had more than one client get backed up onto by a SUV or Minivan that did not see the small sportscar behind them in their rear view mirror.

This lane position is dubious...

3. "See and Be Seen"

Motorcycle headlights are always on, making them more visible. While the Lotus already boasts distinctive lights, consider running your lights or periodically flashing your lights in dense traffic as an added precaution.  Make sure your headlights are working and consider an upgrade.

4. Beware of Blind Spots

Just as motorcyclists steer clear of blind spots, especially those of larger vehicles, Lotus drivers should be doubly cautious. Always aim to position your car in a space where you're visible to all mirrors of the vehicle ahead.  Do not pull up too close to the back of any tall vehicle.  Keep at car length or so behind.

5. Decelerate Smoothly

Abrupt changes in speed can catch drivers off-guard. Motorcyclists often tap their brakes a few times before slowing down, causing their brake lights to flash and alert drivers behind them. A similar approach can be beneficial in a small sportscar.

6. Defensive, Not Aggressive

There's a distinction between defensive driving and aggressive driving. Borrowing from the motorcyclist's playbook means always being alert and prepared but never taking undue risks that jeopardize safety.  I recently read an article from Aerostitch with more great tips and considerations that you may enjoy: HERE

The roads we traverse are shared spaces, and co-existing requires mutual respect and understanding. By adopting some of the tried and true tactics of motorcyclists, drivers of small sportscars can not only enjoy their drive but also ensure that each journey ends as safely as it began. Always remember, in the dance of road navigation, it's not just about the steps you know, but how you adapt to the rhythm of those around you. Safe travels!