Weights Savings in Your Oil Lines

As many of you know Lotus has implemented a recall for oil lines on federal Elise/Exiges that were manufactured between June'04 & Nov'06. If you have a vehicle that is affected contact your local dealer for service. With that said, Sector111 have some solutions for those owners craving additional weight savings.  We know that the innovative ULTRAliteLINES save about 4.2lbs  but cars with a single oil cooler can save more than 6lbs and deliver more reliability....here's how:

Lotus use this hardline so that they can use the same oil lines on one or two cooler cars.  It keeps their SKUs and assembly process simplified. This hardline and two fittings can be deleted with either our RACEoilLINE or ONEcoolerLINES products.  These two solutions provide one continuous line from the engine, along the RH side, across the front to the drivers oil cooler. Deleting two fittings also eliminates 2 potential failure points for an oil leak.
                                

Hardline and fittings from a one oil cooler car represents ~1.85+ pounds alone

(note; we're weighing our lighter fittings instead of the heavier Lotus).

We recognize not everyone wants to delete their freshly installed Lotus lines but some of you may want to eek out just a few more pounds by eliminating the stock RH side lines and fittings. 

If you have been data logging your oil temps and have found, like us, that these cars are taking much longer to get to proper operating oil temperature with two coolers, then you might want to delete an oil cooler.  If your car is only driven on the street then you really only need one cooler.  But we don't recommend blindly deleting a cooler, unless you have been logging temps and know your car is running cool...we'll post up how we've been logging the data in a future entry.

Continuous Improvement - Oil Control

Oil control on track is a weakness of a stock Toyota-powered Lotus. Our baffled oil pan, the gPAN has been a reliable solution that has kept many, many cars safe with good oil control when subjected to 1+g loads. We initiated a serious dry sump effort to develop the next level in oil control but continued to look at the gPAN to see if slight improvements could be made.  Both our dry & wet sump solutions are discussed in this post.

A wet sump solution like the gPAN is truly the best option for most owners as it remains street friendly. I cut my engineering teeth at Pontiac Fiero where continuous improvement was part of our daily mission and expectations. In the 90s, I worked with the Japanese OEMs, while working at 3M Automotive, and saw it applied at all areas of their business. From the Japanese I learned that small improvements, done continuously, can have a big impact over time.

The new gPAN2 is an example of a product that we have been able to improve through small design changes. Our latest improvements are horizontal ledges in the side of the pan. The chart above shows oil pressure data measured from two of our Elises(Nirvana & Blue Car). They were equipped with basically the same modifications: Nitron 46mm Triples, Hoosier A6s, SJ Racing wheels, RACEunderAero, titanQR and KATANA265. The Blue Car had our new ULTRAliteLINES vs. stock oil cooler lines in Nirvana, which may account for the slightly higher average oil pressure. The data is from the Lotus Cup events at Laguna Seca in 2010 & 2011, with yours truly doing the driving. We took laps that were close in time and also compared the g loads (over 1g) to insure we were loading the cars equally. The data is shifted a bit as our Start/Stop point were a bit different for each car so the peaks and valleys don't correspond perfectly.

The variation between the two pans is the most striking difference. Both gPANs do a good job with keeping the oil pressure in an acceptable range - the gPAN2 simply controls the variation better. Will this make any difference to wear and tear on the engine? Hard to say as we don't have the ability to test longevity. The engineer in me says that it must be better as it varies less. Though there would be added cost of material and labor for welding the ledges, I felt it would be an improvement worth incorporating.  It was also a big enough improvement that a new name was in order.  So we put on our creative hats and came up with... gPAN2...8^)

Dry sump development continues in earnest. We took Blue Car to Spring Mtn racetrack two weeks ago to test her.  We first ran her on a dyno to insure we had a working solution then made the trek out to SMMP. The oil tank in our solution is a modified tank from Peterson. Ryan spec'd a design and had it built. He wanted to see how well the solution would work so installed a temporary clear top on the tank so we could view the oil in action. The Dailey pump that we choose includes the air separation stage as external oil pumps can add a ton of air into the oil causing foaming. His separator works amazingly well as shown in our video: Tank in action

We recruited our friend Jack to drive the car at the track in 105deg F weather. He ran the car under specific directions from Ryan so we could check various issues. Oil pressure readings were excellent once we determined the correct oil level. The two issues that we experienced were our breather set-up and low hot idle oil pressure. The breather plumbing from our tank was not adequately shielded from the incoming oil under high revs, so too much oil was getting into our catch tank. You can see a bit of this in the video above. We're now making a change to the vent design. The hot idle pressure required that the pump be removed and tweaked by Dailey. The pump was adjusted after we returned and the tank is now getting modified. We should be ready for testing again soon.

Purple Elise Build Cont...

We finished Jerry's car this Tuesday and put it onto a transporter. We are really pleased with the results. This Elise started out as a basket case and is now going to be a fun, reliable and fast machine. We had the factory forged wheels painted black and added the graphics for that special race car finish!

The ReVerie 3 Element diffuser and Rear Panel Eliminator add some downforce and aggression to the rear while the Jubu front spoiler added the same to the front. When we introduced the naked rear look to the US, six years ago, we met some market resistance. Frankly it now looks so natural and has become very common! Note the plastic mesh that was installed in the front intakes. These are simply zip tied in place and are far more durable than the stock grills. We think they look better as well. This is also a race car mod - it would not pass muster with the white glove set!

The interior of the car features a Sparco race seat that is wider than normal. This seat just barely fits and is a bit of pain to install. The seat is more comfortable because of the added width. It also requires that the center console be moved over so it is not a good street solution.

The KATANA265 is shown below along with our QWKcans. We believe this is the max power that a stock trans can take with track use.

The Larini Header, Decat & 6" muffler sound great with the HKS intake. This combination is amazing.

The Before and After shown below is an amazing transformation. The wishbones were freshly powdercoated - what a difference they make. I think many cars are old enough now that undertaking this freshening is a worthwhile task. Its not just my OCD kicking in...

We installed new discNOIR rotors to save some unsprung weight along with Carbotech XP12 (front) and XP10(rear). We're running this pad combination on our car (with bigger calipers). The car came equipped with stainless lines so we simply added fresh Motul RBF600. We aligned the car to specs we prefer but the beauty of these cars is how easy the alignment can be tweaked.

I am planning on attending the Lotus Cup event next Friday at NJMP where this car will run for the first time. The car still has a couple of issues to sort but I'll work with Jerry's team to get this car shook down! Many of our customers and Dealers will also be in attendance so it promises to be a great time.

All in all, it was a fun project. This build proved to me why the Elise/Exige will be iconic cars. They are so easy to refurbish and tune. Additionally they are cost effective and too much fun to run on track. As more and more enthusiasts come to learn about these cars, they will become more and more valuable!

I would like to thank my team at Sector111 for all the hard work. We finished a months worth of work in just over two weeks! Thanks Guys and Gal!!!!

The Purple Elise Meets The Track Trilogy of Terror

As we created our list of parts to add to the Purple Elise, it was clear that the Track Trilogy of Terror would need to be addressed in full. Our Lotus are truly fantastic cars straight out of the box. They are a blast to run on the street and track. But once you take your car to the track, three issues pop up that need to be addressed. We call these the Track Trilogy of Terror: Oil Starvation, Fuel Starvation and Weak Rear Toe Link Joint. Naturally we will be addressing them in this build. The car will receive our gPAN, V2 Fuel Tank with PNPpump - since she is getting a KATANA265, RTVbrace and S99 Toe Pins.

We've been using AiM data systems for the last couple of years after being prodded by our good friend Ralph@V2. The Blue Car is loaded with AiM data recording systems as is Ralph's Exiges. Together we've accumulated some interesting data that shows that you can fix the Track Trilogies with some tasty bits. View the graphs below:

Oil Pressure Data:

Fuel Data:

Purple Elise Track Car Build

Two weeks ago, we received a commission to build a track-only Elise by a client in NJ. Jerry requested that we build him a fast, fun and reliable car. He gave us a good budget but a tight timeline, so we went to work without delay. Luckily we knew of a vendor who stocked Tasty Lotus Bits....

We found a partially built spec Elise and bought it for him. This car needed some TLC but had a straight chassis and a good engine. The car was originally used as a Lotus Driving Experience car at Spring Mtn. After taking delivery of the car, we fully inspected it and found that it needed most of the typical wear items replaced. We dug into her in earnest and developed our project plan - 78 hrs of work to get her right. I figured we'll spend at least double that as these projects tend to be motivated by passion...a Balanced Approach was our strategy.

During the tear down, one area that I noticed needed improvement was the steering arm bolts. They were the older Grade 8.8 spec that came on some of the early cars - Lotus uprated them to Grade 10.9 in later cars. By installing 10.9 bolts, this joint, which sees significant load, will be stronger. We have some friends who have installed even higher grade bolts than this. The Grade 10.9 is an excellent compromise with added strength over the 8.8 yet still ductile enough.

The existing cage in the car was not installed to our standard. Unfortunately it was too expensive to fix, so we decided to tear it out and replace it with our new R3cage. Welding can be a challenge but there are experts who can do it properly. We would encourage anyone who is getting a cage installed to first inspect the welding capability of the shop you are hiring. Check out this picture to see an example of a poorly welded cage (as originally found on the Purple Elise). We're very happy with our new cage and will be able to sleep at night knowing Jerry will be well protected.

One of the typical wear points on the Lotus is the a-arm (wishbone) bushings. Under heavy braking, especially with track use and/or sticky tires, these bushes tend to wander. Eventually the wishbone will come in contact with the chassis - as shown below.

Most of the top bushes suffered from this on the Purple Elise so we decided to replace them, with MONOballs along with the ball joints - that we now get from our partner Seriously Lotus. We took the opportunity to get the wishbones powder coated as they were quite oxidized and nasty looking. The corners of the car will be sexy with newly finished wishbones, Nitrons, brake rotors and pads.

The rear subframe was another component that suffered some cosmetic damage. A battery had clearly come loose at some point in this car. The acid made a mess in the trunk and the leaked onto the subframe. This caused the steel to rust. My buddy, Ducati John, lent us an experienced hand over the weekend as he was quite interested in this build. We Scotchbrited the rust off and scuffed up the rest of the subframe. We primered it with Rust-Oleum high temp primer and then painted it as well. The cage was painted with the 'Hammered' finish Rust-Oleum. The subframe was reattached to the chassis and looks ten-fold betta.

Most of the work is being executed by Chris. His race experience clearly helps, as he is cranking through this car at a great clip. He installed a gPAN in the time it takes most people to read the install instructions. More blog entries are coming as we have alot more work to do....anyone note the Larini header peeking out the back? KATANA265 is getting installed....

More Track testing: 2ZZopg, Brake Pads, etc.

We were at the track again last week for more testing. We pulled our engine and had Bruce Nogrady install our new oil pump gear, the 2ZZopg. We went to Willow Springs to test after confirming that the gear was running fine on the street. We also needed to test another brake pad compound and an improvement to an existing product. My good friend and fast LCS racer, Jack, met us at the track and was our official test driver. Jack has many, many laps on this track and could be trusted to put the car under high loads to confirm the performance of parts we are developing.

Jack ran the car for a few sessions and I ran one session as well. I downloaded the data from our AiM system between each session. The oil pressure looked fine and the car was running well even in the 97degF heat. See graph with data below. The gear is the same dimensions as stock but made from higher grade steel. Since it passed our testing, we added it to our website today. It is now ready for anyone building a motor and looking to upgrade over the stock sintered gear - which is known to break apart under high rpm, oil starved use.

We continued to test brake compounds with the 308BBK & Front OE caliper relocation set up. We had run the Carbotech XP12 front & XP8 rear at the last two track tests with good luck. We decided to test out the more aggressive XP10 in the rear this time. The car remained stable under heavy braking. Jack even felt it dived less. The added bias to the rear was noticeable over the XP8 but not nervous like the last time I tested different pads at Willow: previous test.

The brackets used to relocate the front caliper have been ordered and are expected to be in stock this week. I think it will be the solution for many of the power junkies out there who are looking for a BBK that still retains their hand brake.

I am very happy with these pads - Ralph@V2 has been swearing by Carbotech pads for years with his racing efforts. We had first tested these pads last year and have recently added them to our stock. Trail braking is great with these pads and amazingly, the dust is low and easy to clean. The only negative so far is that the pads must be bed with care, though we get them pre-bedded to ease this process.

The ULTRAliteLINES continue getting tested along with a couple of new products. We are very pleased with the data that we are gathering. The FuelSafe fuel cell was removed from the car before this test, filter cleaned and replaced. It ran well and remains a great solution though you must monitor the fuel consumption. We are working with them to improve the fuel reading as I had described in a previous post.

The engine was yanked out today by Chris. We take it to Bruce tomorrow to prep it for the Dailey Dry Sump system. Ryan will be done with the tank for this system this month. We will be back to track test it with Dave T. at the wheel. The Blue Car must be ready for LOG31!

Canyon Drive For Fun & Development

I took my Atom3 out on my favorite local 'development' road recently. This road is one I know well and is quite challenging. It is one of our test loops because of the variation it offers: rough & smooth pavement, tight corners, off-camber, serious elevation changes, fast sweepers, you name it, this loops offers it.

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Even with these varied conditions, I recognized that it is not enough to develop every product we work on. A few key durability tests are difficult to replicate on the street: repeated heavy braking, high speeds, sustained Wide Open Throttle (WOT) & 1+g-loads. We've found the track is the best place for those parts that truly need to see more severe testing before getting released. Clearly there is a reason that most automotive companies have their own test tracks!

Over the years, we have taken many, many clients on this loop and most had an exhilarating experience - while a few had a frightening one! I feel fortunate that we have great roads, much like this one, for basic testing and frankly, for fun. Our cars are made for these roads so 'testing' on them becomes one of the great burdens we must suffer...Next time you are in town, give us some warning and we can take you out on our test loop!

Mitigating Innovation Risk Via Testing

I received an email last week from a supplier (and friendly competitor) expressing concern about the clamps that we were using in our new ULTRAliteLINES. His concern was based on the fact that Gates, the manufacturer of the clamps, recommends them 'for vehicle coolant hose only'. I very much appreciated the feedback from him as it made me realize that others would also raise this concern - even though we are using it with hose engineered for coolant, oil and other fluids. So this blog entry serves to show our approach to insuring the performance of our product.

We knew our kit was a novel application of these components and did not know of any other companies that were using it this way. These lightweight Startlite hose, clamps and BSP fittings, were so cool (to us geeks) that we wanted to determine if they were fit for use in our application. Since coolant and oil as fluids look extremely similar to each other from the clamp's perspective. The only system differences are a small temp difference (coolant goes to 240F or so, oil to 270F) and the significant difference of pressure (15psi vs 100psi). The material properties are irrelevant to our hose system as neither fluid comes in contact with the clamp since our arrangement is over a barbed fitting, not a reused hose that could have oil on it. Therefore, pressure capability was the only real concern for our testing to investigate.

We felt spending the time and money to conduct track and lab testing would be the right path for this kit. It added 4 months to our development schedule but clearly needed to be done as we knew of no others who run this combination.

Ryan, who developed the ULTRAliteLINES, and I have a combined 25+yrs in the OE and Tier 1 auto industry. I spent 12yrs developing new products at 3M Automotive and subjecting these parts to OE specification and internal tests. Developing lab tests that would predict the lifetime of a part was always a Holy Grailish endeavor. There are committees of scientists and engineers who work towards striking the right balance between real world testing and simulated testing done in a lab. We decided a combination of lab with actual in-car testing would be the best indicator of how the product would hold up. Frankly, thoroughly testing this creative 'joint' would be the only thing that would allow us to sleep at night!

Laboratory tests:

We found a lab in MI that specializes in automotive line and fitting testing. They would be able to subject our kit to extreme conditions we could never replicate on the street or track. We sent them three samples of our kit and had them run two types of tests:

1. Pressure Proof: 150degC@150psi for 30minutes and check for leaks
2. Burst: increase pressure until failure

These tests represent extreme conditions that would never be seen in our cars. But by testing in this manner, we can fatigue the product and try to extract a failure. Accelerated tests can help predict potential failures, so extreme conditions are warranted. Since our budget did not allow optimization of this joint, we did not test various combinations. We only tested the configuration that we felt would be the best for our kit.

We created a marketing piece that shows the test results. You can see it here: LAB results. Essentially we passed the Pressure Proof tests and showed a safety factor of 3 to 5 times on the Burst test. This test is quite extreme as it is run immediately after the Pressure Proof test. Basically, the fittings blew out of the hose at pressures that were 3 to 5 times higher than they would ever see - even at peak operating levels. Frankly the test showed that the joint was withstanding 6 times normal operating pressures. As an engineer, this is a comforting margin and insures blissful sleep.

Track testing:

Subjecting parts to the track can be some of the best testing possible. This testing will insure that the cars can run even more reliably on the street. We installed the ULTRAliteLINES onto our Blue Car, a 2004 Elise. We initially ran it at the Big Track at Willow Springs, then at CA Speedway (Auto Club Speedway) and then finally at Laguna Seca. Here is a video from Laguna Seca: Blue@Laguna. We were testing several other products as well but the ULTRAliteLINES were run for a total of 11hrs (including dyno, etc) and approx. 360 track miles.

We used our AiM data system to record key parameters like oil temp and pressure. We also reviewed the lateral acceleration numbers to see how the pressures were holding up with our gPAN. The car showed oil temps of approx 200degF which is well under the 300deg F used in the Pressure Proof testing. The actual oil pressures we logged ranged from the high 40s psi to the low 60s psi. This was a third to half of what was used in the lab testing and far, far below the Burst test results of 344, 452, 565 psi. Ryan's OE experience suggested that a peak pressure of 100psi would be the extreme level experienced by our lines.

Other Considerations:

Proper component selection is key for a reliable system. Each of the parts we chose, come from reputable automotive companies who have done extensive testing. We simply supplemented their work with tests that were specific to our needs.

The Aeroquip Startlite hose has been used for fuel, oil and coolant applications successfully and has been fully tested by Eaton Corp. The braided hose actually imparts a clamping force onto the fittings, much like a 'Chinese Finger Trap' when you pull it. The Lotus twin oil coolers utilizes a fair amount of rubber hose. This became a clear opportunity, for weight reduction, if we used Startlite, since it is 40% lighter than typical rubber hose.

The Gates clamps were the newest and novelist item in our system. They have the ability to dynamically adjust compression based on temp. They also work very well when applied over hose/fitting barbs as they have much more clamp surface area and better conform the hose to the fitting barbs. The Gates clamps also claim to be impervious to ALL automotive type fluids.

Combining all these features made good engineering sense to us. We just need some testing to insure we were onto a good thing...and separate us from the typical approach that is used in the aftermarket.

Options For the Ultra Cautious:

I recognize that some in our community may still want more security. For them, I suggest the tried and true hose clamp. They can easily be added as a secondary clamp over our Gates clamps or as the primary clamp. They add just a tad bit more weight...I suspect Colin Chapman would simply run our kit as is...

Blue Car Testing @ Laguna Seca

The next round of Lotus Cup took place at Laguna Seca. We brought our Elise out for additional testing:

1. Oil Cooler lines
2. KATANA265
3. Brake Relocation: Carbotech pad test
4. Larini 8" (ultra quiet)
5. FuelSafe Fuel cell
   

The boys had to swap out the trans after our last trackday and refitted the conventional gearbox with the Jubu 3rd,4th & Final Drive with the OS Giken LSD.

Oil Cooler Lines: We ran these lines again this weekend and had no problems. Our kit uses Aeroquip's Startlite hose with BSP fittings and a novel clamping system. Our clamp is very clean and compact which will make installation much easier. Our independent lab testing and the 6 trackdays has made us confident that our solution is ready for sale. We should have them available within a week or two.

KATANA265: Another three days of full throttle track use has us pleased with this solution. The AFRs & EGTs are looking safe and we believe we are ready to release the kit.

We believe that Hp north of the KATANA265 will result in problems with a stock transmission. We've witnessed another racer's 300+hp Exige lose 3rd gear at Laguna. We recognize that the allure of big Hp is hard to resist but we hope that folks will recognize what they are getting into. We are still waiting for a reply from Jubu/Drexler on the status of our Dogbox failure from the Fontana event. I think trans failures will become more common as the cars get more power and run slicks on the track.

Front Brake Caliper Relocation: I ran the car with the Carbotech pads and was very pleased with the XP12 & XP8 in the rear. The car did not have any of the nervousness that I had experienced at Willow Springs during our initial test. The pads work well and can be trail braked easily. They are not very grabby and allow a smoother release. I think that a more aggressive pad can be tried on the rear for sure. We'll get to that next time!

Larini 8" ULTRA Quiet: We ran a stock Exige S muffler to start our weekend to make sure the car was very quiet. Laguna has a very strict noise limit which has resulted in many racers trying different muffler contraptions: see previous post. Our car has several upgrades that would add to the noise like the HKS intake, Larini header/straight pipe and Jubu Final Drive. But with the stock Exige S muffler we blew a 88dB - so were well under the limit. The car felt a bit slower possibly because of the added restriction. We brought a new Larini 8" ULTRA Quiet with a special wrap that quiets the system over a standard Larini8"by an additional 2-3 dB. I wanted to test this system to see if it might be close. We installed it before the last session and went out for a sound check. The car sounds much better but I also knew right away that it was too loud! The car felt much faster going up the hills than before but ultimately blew a 98dB!!! Well, they black flagged me pretty quickly and I returned to the pits. Sound can be a difficult thing to measure properly in track conditions but we are so far over the limit that this muffler will not likely work for other heavily modified cars. This muffler will work perfectly with a NA car and possibly with an Exige S with stock intake/header/cat.

Fuel Safe Fuel Cell: We continued to run the car with the cell. Everything worked fine with the exception of one discovery. The system baffles the fuel in the fuel pump cavity too well. This results in the fuel gauge reading a higher amount than what is contained in the whole tank. Essentially the car can be down to a couple of gallons of fuel and system will trap it in this cavity that holds the pump and the fuel level float. The float will assume that the tank is higher than it actually is. The stock fuel tank has a bleed so that the fuel can slowly level itself when the car is sitting. We've contacted Fuel Safe to see if there is a good solution or drivers will need to monitor their fuel consumption.

Overall the weekend was a great success. We supported two Spec Elise clients along with Blue. None of the cars broke down and I was able to get my times down to 1min43s. I made one shock change that felt like an improvement but did not have much time to tinker with settings. With some coaching (and some new tires)I think I can carve another couple of seconds - maybe even break 1min40. That 'll have to wait till next year or my dreams! Our AiM data collected plenty of great info including the fact that car pulled 1.5gs - so I know we continue to stress the various products well. We have many more items in our pipe so this arduous testing must continue....8^)