shiftR111 2.0 Prototype Testing

We have been testing the prototype in Lee's 2011 Elise for the last couple of weeks.  He has been very happy with it so far.  The second proto has now arrived and we have a couple of changes that we need to test out to improve the kit.  This one will go in the 111RS and then we will modify the first one and install in the ArtCar2 for track testing.

The two issues that this first one had are the reverse lock out block is not thick enough and the base plate has a hole that does not line up perfectly with the floor of the car.  Both will have an effect on the feel of the kit so we want to get them right. 

One thing that is clearly better is the action of the reverse lock out collar.  Eliminating the cable deletes one adjustment that makes the install even easier.  We believe it should also make for better durability and reduce the need for any future adjustments.

111RS #3 Build: Finished?

The 111RS was mostly complete!  We got the car ready for a soft unveiling with the Avants club.  We did not get a chance to rack up enough miles to ensure she was properly vetted.  Plus the AC was not yet charged and the stereo wiring was not yet completed.  At least we got her through Smog Test and got the plates up to date. 

I had my Brand Assassins team get to work on the car and add some decals - especially the EVH homage to the roof.  

She looked great!  Initial driving impressions were also excellent so I can't wait to start racking up break-in miles...

We hung out with other enthusiasts at Auto Conduct's facility in Los Angeles

111RS #3 Build: Finishing Details

LEDs in da HOUSEing

There are so many details that need to be taken care of on a complete build like this.  With our unveiling coming up this Saturday, we were under the gun to finish her off for the assembled guests at the Avants Club Master Class. 

Stereo install, raceVIEW mirrors, ReVerie Side Scoops & 5-element Diffuser, LED lights and custom front turn signals, V-Force harnessbar, Schroth PROFI 4pt Harness, powder coated gas cap cover, alignment, seat install, Safecraft Fire Extinguisher, LFTstrap, BBhook2, red Bollock, sillSACK, custom door panels and custom steering wheel.  

Carlos aligning her to our spec

Plus we got Brand Assassins to add some decals to the car.  One key design element looks especially cool and is a tribute to a favorite musician of ours.  Final pix coming soon...

Interior: Rubber Floor mats, Bollock, Fire extinguisher, more

111RS #3 Build: Clam & Seat

 The front clam is back and getting secured to the car.  The access panels and rear engine lid were also repainted.  We need to rewire the turn signals and add LED rings to the light cluster.  

Another cool development is a new supplier that we have been working with on upholstery.  We had them redo a passenger seat along with the door cards.  The seat came out of an Exige originally.  I kept the same overall design but changed the materials.  In fact, I choose Alcantara, Perforated Leather and CF-look pleather.  All of these are in black and look great together.  I'm a big believer in changing up textures but staying within the same color to add a bit of cachet.  The seat turned out subtly cool.

We also added an inflatable lumber bladder that works well.  I'm especially pleased with this.  Many of the stock seats came with this feature but have failed.  We can retrofit our kit when we reupholster a clients car.

111RS #3 Build: Front Clam Turn Signal Delete

 We've been deleting the front turn signal on some of our cars.  The stock turn signals are known to pop off as they are fixed with plastic clips that fatigue and fail,  Initially I did not like the look sans signals but have warmed up to them.  Form follows function for me - usually!

We plan to run the car without the center grill so have deleted the holes that they clip into.  Plus we've removed the seam that runs under the nose badge and lights.

111RS #3 Build: Rear Tailight Refinish & Interior Upgrades

 The rear taillights can get dull over time but can be refinished.  You can sand and polish or even have them clear coated.  Lee took the lights from our current 111RS build and worked his magic.  He starts with 1500 grit and wet sands the lights.  In some cases he will start with 1000 grit and then follow with 1500.  

Then he used a cutting compound and then a final polish/wax.  The end result is pretty impressive and something that a DIY could tackle.

We've also decided to dress up the interior of this 111RS.  Several clients have added Alcantara (suede) to their dashboard area and it really looks great.  Are we kidding ourselves attempting to make this car a bit more luxurious?  It is hard not to like how much nicer these parts now look and feel!

The driver seat will again be a comfy CF seat.  We're reuphostering a factory Exige seat for the passenger side.  We want to experiment with a lumber bladder upgrade on this seat.  We know many of the stock lumber bladders are failing along with the leather getting worn out.  We think we can offer to restore these worn seats with new leather/material as well as adding a new inflatable lumber bladder.

We even are looking at heated seat elements for those of you in chillier climates...

Mold Warning: Beware of Storage on Gravel!

 We received a car that had severe mold growth all throughout the interior of the car.  It had been stored on a gravel surface and covered with a special car cover.  The mount of mold in this car far exceeds anything that we had ever seen.  The smell was really strong and certainly not safe to drive - especially if the AC is on.  Mold needs three things to grow: food (organic material), moisture and dark,  This car clearly was heaven for mold growth!

We had to completely take the interior apart and clean all surfaces.  The rear clam showed huge mold growth so that had to be removed as well.  We decided to yank the front off as well.

rear clam viewed from inside the cabin

It turns out the car had been stored on gravel with a special rodent-resistant car cover.  This cover shown below features a weighted circumference that 'seals' the car and prevents rodents from entering.  Though the cover claims to breathe, it was probably not enough to cope with the prodigious amount of rain we experience in CA this past winter.  The porous gravel surface was certainly another contributor to the problem as it releases moisture.  As the temps came up, the moisture evaporated from the gravel but was trapped within the car as it was sealed by the cover.  

Our recommendation is to avoid storing your car on a porous surface like gravel or dirt/grass.  Covers with weight bottom seals are going to be especially troublesome on a porous surface.  If you can drive your car every couple of weeks, that should also help reduce these issues!

Lee steamed, disinfected and coated the engine bay. 
Carlos refinished the rollbar supports in satin black.

111RS #3 Build: AC & Stereo Improvements

 

We are attempting to improve the lackluster AC and stereo performance on this build.  We've not attempted much in either of these categories in the past so wanted to make some progress here on this car.

We have had clients ask us to improve AC performance for years.  Next year, we plan to look at new HVAC units but this year we have too many other product developments that are consuming our resources.  So simple ideas are what we are testing here.

Adding insulation to a few key areas is one idea.  We first insulated the inside of the actual HVAC unit.  We had to rebuild it due to the rodent damage so it gave us the opportunity to add some insulation on the inside.  We brainstormed that this may be an more effective method at keeping the cold on the inside.  We have also added it to some of the ducting in the dash.

Inside the HVAC housing

Under dash ducting plenum

The stereo is also getting improved on this 111RS.  I have removed the stereo from my last two Elises as I have not put much thought to sound systems in these noisy cars!  Ironically I love music so a nice sound system seems like something I would have already sorted.  This car will get our first attempt at creating a better system that does not add too much weight or wiring complexity.  The high level plan is to create a subwoofer box that will take the place of the passenger foot rest.  This box will also house an amp and Bluetooth to connect a phone that will stream music.  We will use the stock speaker locations with upgraded speakers.

This car had some messy aftermarket wiring work done.  Carlos reversed it so we can create a plug and play harness adapter for our solution.  One of our good friends also has been experimenting with sound deadening ideas in his Elise.  We are using a product he recommended under the seats.  It is heavy but lets see how effective it is...

We will reinstall the 5lb foam insulator behind the seats.  This was an easy weight reductions we used to employ!  This car will have more power courtesy of the KATANA3 so we can afford to add a bit more weight.  When we are done, I think we will still be lighter than a stock Elise - but the scales will tell all!

Touring Pack came with some insulation

An act of heresy: sacrilegious insulation

111RS #3 Build: DNA Sway/Engine/Gearbox/KATANA3

We're making steady progress on the 111RS.  The rear of the car is coming together.  We are on track to having it finished by early May.

We decided to paint the rear swaybar mount black.  We peeled the DNA sticker off and revealed the silver powdercoat underneath.  You can see it above.  We left the swaybar itself in silver so it would stand out against the black mount and rear subframe.

 The Mountune-built 2ZZGE engine has been dressed and reassembled with an enhanced alternator that we get locally rebuilt.  We also reinstalled the KATANA3 from our last Outlaw.  We intend to run this kit through CARB so need to get this onto one of our cars.  The rebuilt gearbox was also mated to the engine and is getting a new clutch and flywheel.