sonicFURY Fitment on S3 Elise with 2ZR engine

 A client of ours from the Eurozone, David F., installed our sonicFURY DE, in his S3 Elise with the 2ZR engine.  It fits!  Needless to say, we are stoked..and so is he!

Fuel Cell Are A Consummable!

 We're servicing a race Elise and noticed a strong smell of fuel.  Turns out the car had a fuel cell and it was leaking.  

This particular tank was made way back in 2009!  Generally they will have a 5 year life so inspect yours.

This client wisely chose to have us install one of our baffled 111tanks so this would no longer be a headache.  We also upgraded his stock pump to our DW65c Fuel Pump.

Of couse, his car was missing some key bits but we were able to source the parts and plumb up our tank so it would be effective and safe.

HVAC Cavity Drain Holes

In the last year, we have seen a few Elise/Exige cars with drain holes that were either not drilled or not fully drilled out.  We would encourage you to inspect your car to confirm that the holes were drilled correctly.  Your fan blower is in jeopordy of failing if this is not done.

What?

The S2 Elise and Exige should have drain holes drilled into the chassis.  This was a Dealer installed Technical Service Bulletin 2007/01 issued by Lotus Cars.  The TSB is posted at the end of this Blog post.

Why?

These holes allow water to drain from the HVAC cavity.  If water is allowed to collect in this space, the electronics for the blower will begin to corrode and then fail.

How?

At the front of your chassis you can inspect to see if these holes are present.  Take a 6mm rod and see if it will go all the way into the cavity.  If not, you can drill it yourself with a 6mm drill bit.  Note the 10mm limiter suggested by the TSB below.

Updated Ride Height & Alignment Suggestions

Our Street Ride Height recommendation has been update to reflect our new thinking for improved clearance on some of our ever deteriorating road conditions.  We raised our recommendation by 5mm.

A proper alignment is critical to the performance of your lightweight sports cars.  These cars are very sensitive and respond well to changes in the suspension setup.  These recommendations are based on experience we've gathered since 2004 with the Lotus 111 platform.  Your results may vary so we suggest you start here and tweak as your driving style demands.  

Make sure that your car's suspension components are in mechanically sound condition.  Check your ball joints, toe links, track ends, etc to ensure that nothing is worn out.  See our 60pt Prep Sheet for a great reference.  Consider our Suspension Refresh Kit if you discover worn-out parts have a higher mileage car.

Recommended settings for an Elise/Exige street/track car with R-compound tires.         

                          Front                 Rear
Ride height    130 +/- 3mm    135 +/- 3mm
Camber          -2.2° to -2.5°    -2.4° to -2.7°

Toe (total)       0                       3mm total toe-in

Our ArtCar is running even lower thank to our raceUPRIGHTs

Recommended settings for a track Elise/Exige car with slick tires.

                           Front                      Rear
Ride height    120 +/- 3mm              125 +/- 3mm
Camber            -3°                             -3°
Toe (total)       0 - 1mm toe out        3mm total toe-in

--------------------------------------------------------------------------------------------

Follow These Steps:

1.      Set the ride height.  

2.      Set camber.

3.      Set toe.

• To set the camber, remove all your stock shims as well as the ABS shim. You may need to install FASTarms or machine your stock steering arms to obtain optimal camber.  Remember to use thread locker on the steering arm bolts.
• While a lower ride height is possible, we find the suspension works best at these recommended heights and the chance of scraping the bottom of your car is less.
• Write Down All of Your Changes!  Write down your alignment settings and then note how the car performs. Write down any changes you make and record the results. This is the best way to get the car dialed in exactly how you like it.  Use our Alignment/Set-up Sheet to help keep tabs on the changes.

Evora GT Tuning: Power & Compliance

 We have been working on a '20 Evora GT to increase power but also improve handling for this client.  He wanted better front end grip and more compliance for the rough tracks that he frequents.  We received the car and started our upgrades and tuning.

Power

We installed parts from Komo-tec along with sending out the SC for a port and polish.  A slightly smaller pulley was also installed along with a Cold Air Intake, Headers, Sport Cat. and Sport muffler.  Brent came down to tune the car once we had the upgrades installed.  We were able to get the car up to 450rwhp on a local dyno, which translates to about 500hp at the crank!  We believe this is the only 500hp Evora in the US running a stock ECU.

Handling

The owner of this car has a fair amount of experience driving race cars.  He loves this car but felt the front end was not gripping the way he wanted.  He also wanted more compliance to absorb bumps and rough sections.  We sourced a set of Nitron Triples and he secured new upper wishbones to be able to add more negative camber.

Nitron stopped by to see the install and we were able to optimize the routing of the hose and reservoirs. We used our V2mounts to make securing the reservoirs even better.  Dialing in the ride height went well with the client requesting 5mm more rake than stock.  The car's ride height was dropped more than stock.  We were able to add much more negative camber as well thanks to the wishbones.

Checking ride height

Supercar Performance

She drives great with excellent compliance.  The turn in is excellent and grip superb.  The power is also very good.  This combo on an Evora 400/GTs is pretty impressive.  I think it is a perfect supercar combination!  These Evoras may be the hidden trackday gem that many people don't realize exists!

Lotus Pedal Box Modification for Long Legs

 

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.

The picture below show him with the clutch depressed fully. He needs a bit more.  We've take additional measurements and believe we can sneak an additonal 1-2".  Stay tuned...

Coolant Overflow

Lotus Elise 2ZZGE

Plastic coolant overflow bottles might seem insignificant at first glance, but their role in maintaining the engine's cooling system integrity is paramount. In this blog post, we delve into the degradation of plastic coolant overflow bottles, specifically focusing on those utilized in Toyota 2ZZGE engines, as found in iconic vehicles like the Lotus Elise. These cars have become suffliciently old that parts like this are beginning to fail.

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

Despite their importance, plastic coolant overflow bottles are susceptible to degradation over time, especially in demanding environments characterized by heat, pressure, and vibration – conditions often encountered in a Lotus Elise or Exige. Several factors contribute to the degradation of these bottles:

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

Coolant Loss: Cracks or leaks in the overflow bottle can result in coolant loss, leading to inadequate cooling and potential engine overheating. This not only compromises engine performance but also increases the risk of engine damage and failure.

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.

Why Competitive Tunes Must Be Reflashed to Stock

We have been getting more and more ECUs coming to us with competitive tunes on them with client's wanting improvements.  This is something we can accomodate but it does require additional steps.  We are able to develop tunes but our PG3 Programmer can only read ECUs with stock files.

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.

 If your ECU has a competitive tune, you will need to revert it to stock.  If you are unable to do it, we can do it (at additional cost) for you.

A stock file will look like this image below.

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.

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.

NVH (Noise, Vibration and Harshness) is a criteria that must be considered with mount upgrades.  The options we developed help to restrict powertrain movement to improve both throttle response but also shift action.  The increase in NVH with each option varies.

• sportINSERTS

This is the solution we recommend for street cars that get driven aggressively.  The are inserts that are added to existing mounts to reduce their movement.   This solution can alos be used if you notice that your stock mounts are getting worn or have small tears in them.  We covered this issue in a Blog post: HERE.  They can extend the life of your mounts.  We recommend them for cars that are 80/20 cars - Street/Track.

• TRACKmounts

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.

• RACEmounts4

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.

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.