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.

1111RS at WCLM Concours

 

Trailered to the show on Coronado Island

Looking mighty splendid on the lawn

'Custom' vanity plate affixed

111key in position

111RS decal is billboard-like

111RS Build Interior, Exterior & More

 The final stages of any build can be time consuming.  The CF seats coupled with the stock 3pt and 6pt Schroth harness gives the client options - street or track.

Our client opted for our new customized steering wheel that has carbon on the rim along with alcantara grips, silver stitching and a silver stripe at 12 o'clock.  It adds the right amount of cool to the interior.  

We painted the HVAC surround black to banish any of that cheap-looking grey plastic from the interior.  The shiftR111 was left exposed.

We installed some 111RS and LOTUS graphics onto the car.  We got our good friend, Lee to come in and detail her to get ready for the WCLM Concours.

Loading her up for the WCLM Concours

111RS Fitting Bodywork and Interior

 The 111RS build has reached the point where more cosmetic components need installation.  As many of you know, the bodywork on the Elise/Exige simply hang on the chassis.  These parts are essentially cosmetic and not structural.  This car had body work done to the clams previously, so fitting them took some extra effort.  We've also started installing the interior.

Fitting the rear clam

Front clam fitment took some TLC

ReVerie side scoops were added for some added airflow and style.  These scoops are made with prepreg carbon fiber and then autoclaved.  This results in the lightest and stiffest combination.  A 5 element rear diffuser is also on tap for this car from them.  It is my favorite but does require an above diffuser muffler like our sonicFURY. as there is no hole for a muffler tip.

Seat pads to be fitted later

The interior is getting our CF Big Botom seats for ultimate comfort plus compatibility with 3pt stock belts and racing harnesses.  These seats were originally patterned after my '06 Exige.  I took the brand new seat from my Exige and handed them to our supplier to make these seats - but with one requirement.  Reshape the bottom to accommodate larger backsides and sits marginally lower for a bit more headroom.   The stock seats are notorious for cutting off blood circulation on the legs of bigger drivers.  This seat fixes that problem and has kept more than one client from selling his beloved Lotus!  We made sure they would bolt to the factory seat rails as well.  They look great as well -  especially with alcantara pads.

Our trusty V-Force Harness-bar is in place

Tail lights in place

111RS Build Continues

 We are in the final push to the car ready for WCLM unveiling.  Carlos and Rene are bolting on more items.  

Suspension compliance is a key goal with the 111RS.  We want a car that you can blast through bumpy back roads.  CA canyons are rough in many places.  We spec'd Racetech SCCAs with soft springs (250#/350#).  These shocks also run the same lengths as a stock damper so the ride height won't be too low.

We've coupled the Racetechs with DNA swaybars, Front & Rear.  These have become a real game changer allowing for soft springs which deliver the compliance we want.

Front Racetech SCCA + Eibach Spring 250#

Rear Racetech SCCA + Eibach Spring 350#

The owner of this 111RS intends to drive the car on track occasionally so we chose to add the DNA Front swaybar to give him more tunability.  We've developed a Track setting that is stiffer when you couple the DNA Rear swaybar with their Front.  We're adding the DNA Adjustable End Links to allow for corner balancing - which we will do to her once we get through a couple hundred break-in miles.  Modern springs generally don't sag.  We use Eibach springs and they have been very reliable.  But leaving the corner balance until the end will ensure that it stays balanced for thousands of miles.

The sonicFURY OG is getting fitted along with our Rear Panel Eliminator.  This was the first sonicFURY (hence the OG) and it was modeled to look like a previous muffler we had sold called the TRACKpipe(discontinued but shown below).  I generally like a very functional, bare bones muffler tip.  They look very purposeful and serious.  Our sonicFURYs have become the favorite system for our community thanks to the no-drone while cruising sound that still shriek's on-cam.  Of course, if you prefer a bit more bling, the Stinger version is available.

TRACKpipe installed on our Exige S called 'Switchblade'
 

sonicFURY OG looking quite purposeful

The muffler tip exits above the diffuser allowing the diffuser to work without interruption.  The naked rear will also help shed heat that can build up in the rear of the car due to mid-engine packaging that is very tight.

By painting the rear subframe black, the cool bits will be on display.  It's a small way to make the naked rear look somewhat more civil.  8^)

111RS Progress

Now that the engine is running, we could start to button up the rear of the car.  The Racetechs along with the DNA Rear Swaybar plus our TLUkit are now in place.  New outer balljoints were fitted as well.

Carlos paint markers all the joints that he torques.  This allows for easy visual inspections before/during/after driving events.  We did a blog on this subject that you can read: HERE

 We cleaned up the stock cat with a wire wheel.  Looks much better now.  

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.

111RS Brakes + shiftR111 + More

 We are at that stage where most of the parts are in house and we simply need to bolt them on.  We have less than a week before unveiling her at WCLM so...

The brake calipers were vapor blasted and look amazing.  Rene took the opportunity to spray them with some matte clear coat.  A local shop suggested this will hold up fine but I am curious to see just how well the clear will withstand the nasty environment found within a wheel.

Our ULTRAdisc rotors have been the gold standard for these cars since 2005.  Clients have been getting 50k miles out of them and over 50 track days.  We made them too good!  Seriously, we are proud of how they have performed and super happy to be partnered with a first-class company like Girodisc.

The DNA front and rear sway bars are part of this build allowing us to run softer springs: 250lb & 350lb coupled to our Racetech SCCA Singles.  The sways manage roll stiffness while the soft springs provide the compliance needed on a fast canyon cruiser.  In the past, we ran heavier springs to flatten the roll on the car but gave up compliance in the bumps.  No longer - this is the sweet combo!

The shiftR111 Ultimate package is going in and will make each shift a joy.  This car is getting the close-ratio KAAZ gear set.  We have not driven this solution on the street so are interested to see how it fairs.  Our client has another Lotus with this gear set and is a believer.  

111RS - HVAC Updates

 The early cars are known to suffer HVAC blower problems due to their electronics getting corroded.  These electronics are located in the front of the car and often end up getting submerged in water that collects in the front cavity.  Lotus issued a Technical Service bulletin many years ago that instructed Dealers to drill holes in the bottom of the chassis to act as drain holes.  But even with these holes, we are seeing failures.  

Lotus developed an updated electronics package that they started installing in 2008.  This kit is available from the Dealer and we have been installing them on client cars for many years.  

The 111RS needed this along with another update for the AC thermostat.  The car is going to live in the desert South West so AC performance needed to be as good as we could make it.

The cavity that this HVAC sits within can accumulate plenty of funk.  Carlos took the time to clean it out so when the HVAC was reinstalled, it went into a clean cavity.

111RS Dash + Steering Wheel

 We've become big fans of the AiM MX2E dash.  The original cluster was looking a bit tired so we opted to upgrade to the digital solution from our favorite race data company.  

The car came with a custom steering wheel but the colors were not going to match our color scheme.  Plus it had carbon fiber elements that also clashed with the CF seats that the car is getting.  We decided to install a refreshed stock wheel.

111RS Build Continues

 The body came back from the Body Shop and we were able to pull off the subframe to clean it up.  The subframes are made of steel and not the prettiest part on the 111 platform.  We painted it black to help freshen it.  She looks much better now and will frankly just disappear.  

The Mountune engine needed to get dressed as well.  We installed a new cam gear as the stock parts are known to be a problem spot.