DJ Wilmas Lotus Elise S2 111 Turbo ECOBOOST

[djwilma]

Some of you may have have seen my 1.4 turbo'd Metro on here which i have now sold. So with the money i got from that i bought a 2005 Lotus Elise S2 111S, its a CAT C write off but all the bits to put it back together are with the car and the infamous Cheeky Scott will be putting it back together.

The plan is to then turn it into a 300bhp 1677cc k series monster, and see if i can reduce the weight to below 800kgs

Engine spec will be

DKE Forged Crank
Wossner Forged Rods
Scholar (pistol iirc) Forged Pistons
VVC Cylinder head Ported and Polished with 32.5mm inlets, 28.5mm exhaust valves by Paul Ivey
Custom equal length Exhaust Manifold
VVC Inlet (may go custom if anyone know of a good builder)
56m mThrottle Body
DTA Pro S80 engine management
GTX2860 Turbo
Custom Charge Cooler AVT barrel type

[ryan.minshall]

gonna be keeping an eye on this one

[andywilson]

love it

i've got a vx220 turbo as my daily drive and they're fantastic cars to drive!

will be interested to see this unfold!

[raymondmarble]

Now this is right up my street! All the best with the build, I will be watching. My friend had a turbo series 2 a while back, a Komotech I think?? Anyway, it had 250bhp and was seriously quick, so 300 will be spectacular!
Cheers!

[dangerousdave]

Cant believe youve pussied out of round 2

Still these things go very well with a bit more grunt, there was one that used to go to trigs days with a vw 20vt in it and that was unreal, lifting the inside front exiting the bends

[finlay]

wickid !!!!!!!1

[Hoogi]

Had quite a few Lotus myself, great cars but the 111S I had with the VVC K Series Engine wasn't very good at all.............so glad you're going to inject it with some steroids !

Should be epic after that...............best of luck.

[djwilma]

Cant believe youve pussied out of round 2

Still these things go very well with a bit more grunt, there was one that used to go to trigs days with a vw 20vt in it and that was unreal, lifting the inside front exiting the bends

Pussied out , you'll need 500bhp to stay with the elise.....didnt say what i'd have for round two

For the record when we took the engine out the metro the intercooler was split, so was down on power

The VAG elises are about 60kgs heavier and dont quite handle as well, the idea is to have something thats nearly as quick on the straights but better in the corners

As for the 111S, i actually got it wrong its just a 111 so doesnt have all the creature comforts so is lighter

[dangerousdave]

the metro was awesome as was the vag Elise, this should be something else!! Good luck with it all

[djwilma]

Got some bits for the car today, also got the car home....well to cheeky scotts lock up for spraying !

82mm forged piston, but may not use these as the 82mm liners are getting very expensive and may not be strong enough



DKE 79.4mm forged crank





On the trailer

[djwilma]

Ok few things today, we removed the clamshells and refitted the replacement ones and made a list of what is missing needed

main concern is that it looks like the front clam was "knocked off" in the crash and has ripped all the wiring from the loom. Can anyone confirm if this loom is seperate or part of the car as i will need a replacement.

Hopefully now fixed the links for the photos


How it looks today

[boXXer]

my mate had one of these with 350hp and it was a fooking rocket.

[djwilma]

my mate had one of these with 350hp and it was a fooking rocket.

Havent driven a rwd car for years so may need some drifting lessons next time at castle combe

[boXXer]

lol they are a bit twitchy for that i think

[Hoogi]

Looking great now..................by the way do like the look of the 1275GT Mini in the background - well guessing it's a 1275GT anyway.

The Lotus is going to scary quick !

[djwilma]

lol they are a bit twitchy for that i think

only one way to find out !

As for the clubman its a std 998cc, the 1275GT is in the lock up behind waiting for a 1.8 k series turbo to be bolted in....200bhp and 600kgs should be a giggle

The metro is the slowest with only 160bhp

[row10036802]

Looks good so far, I've had a couple of these through my workshop, re shelled a cat B one onto a brand new tub got loads of pic if you need any. The front loom is indeed part of the main loom I'm afraid but if I recall fairly simple how far up was it ripped off? Have you still got headlight plugs?? You can see pics of it here it's the multicoloured one www.rawautoworks.co.uk its in the gallery.

Hope this helps

[djwilma]

thanks and no the plugs for the headlights are missing so is the horn, have been offered a replacement for 60 that will need to be wired in.

Have the original lotus wiring diagrams too just need to get the front clam off and see what's what

noticed your in chichester you dont have an S2 engine loom i can convert for the DTA and the front grills with the later spots ?

just noticed you do carbon fibre too, need to get some scoops for the side vents to get more cold air into the engine bay, can you help ?

[row10036802]

Yeah not far, sorry not got one hanging around but I got a few mates I can ask for ya as I say if you want any pic I probably got one if you want to see if something is missing? You got headlights?? I spent £1200 just on the front lights!!!

[djwilma]

Thanks again, I have all the lights and fixings etc, just the front grills and fog lights and drivers side scoop

the man who sold me the car is sourcing these and with the front loom he is charging about 100 so not too bad, you;d be surprised what i paid

[row10036802]

Yeah i bet you got a steal, i paid mega money for mine but it was only 6 month old! cant wait to see it should be epic. I'm doing a Mk1 Escort cossie at the mo so that should be my toy for the summer.

[djwilma]

Took the door off today and it looks like it is beyond repair which is a sod, will have a better look later

Got some Paul Ivey valves today

8 off 28.5mm exhaust valves
8 off 32.5mm inlet valves

I have a Polished and Ported VVC head that i am going to use but will be off to Rog at Sabre to have a look and give it a little fettle

Spoke with Newmans Cams today and sent them the spec so we will see what they come back with regarding Cam design

IMAG0148 [800x600].jpgIMAG0149 [800x600].jpg

[djwilma]

Got the door off today, its a bit of a mess but should be able to repair it as dont want to buy another door

IMAG0158 [800x600].jpgIMAG0159 [800x600].jpg

[djwilma]

Drew at Roverdose has stripped the 1.4 spi engine i gave him and the good news is it is the damp liner block which should help with strength





Jonathon at JDM Dyno has kindly made an exhaust turbo manifold for Tinytim on here and i asked for a jig to be made so he will be making a second one for me

It looks a tight squeeze but should be able to get everything in and will cut the panel behind the drivers seat to get the turbo in

Turbo will be a GTX2860 and will be ceramic coated as will the exhaust to keep heat down.

[raymondmarble]

Thats lovely work on that manifold! Beautiful!
Sorry, I'm a little confused here, is the engine going to be a 1.4 or a 1.7?
Cheers!

[djwilma]

Sorry, I'm a little confused here, is the engine going to be a 1.4 or a 1.7?
Cheers!

neither now, will be a 1.6 with 80mm bore and 79.4mm stroke so nice square engine

Was going to use 82mm bore but the machining needed would make the engine weaker IMO plus cost another £800 more. Plus using the early damp liner i get the additional strength due to the webbing below the liners

[djwilma]

Ok some of you may have seen that all my k series stuff has been up for sale

Basically i tried as best as i could to get the k to over 350bhp, but everyone that has gone to this level other than the 1.4 boys have had issues so i just couldnt take the chance. Thats not to say its not possible but i dont have the time and money when i had the metro to buy, try and fix.

So i sold everything in a bid to raise some cash for a new engine.

This has been done to an elise before but only as std spec and they are quick then, but i have bought a forged T series, well pistons and rods, and in this spec with the right turbo they are good for 500bhp+ This one has a GT3076R turbo and custom manifold but neither will fit the elise and i dont want nothing / everything so changing a few things. ECU is an E48 DTA but will be going S80 so i can have traction control (elises swap ends easily and i havent had a RWD car since i was 17, and i crashed that...twice)






Power Curve with the current setup



Bought some bits from Grant at www.gb-ent.com

GTX2867R 0.64a/r turbine housing should be a nice and quick spool actuator 12psi
Gizzmo MS-IBC to control Boost
MTX Wide band controller
Water pump flange, goes onto block for electric water pump
Davis Craig EWP 80lpm with controller
T Series exhaust flange, to add to K series manifold

Collected engine today from Chelmsford after work so tomorrow evening i have a go at squeezing it in, mainly as i have no room at the moment

[djwilma]

Engine is out of the Alfa, which needs a clean, and its now at the lock up with the lotus.

Removed the manifold that was on there today as it just wont fit in the Lotus, the turbo a small GT3076R was also removed



Here is the difference, the old 160VVC engine next to the T series....




Cheeky Scott, Bournemouths finest panel beater holding up the turbo and manifold which i have sold with the loom and E48 ECU already to cover the cost of the GTX



Then when i was home i got the k series manifold out and checked it against the T series one from www.gb-ent.com should fit.



Ordered bits yesterday and they arrived today, nothing like good service from Grant. Turbo should be with me Thursday so i can look at getting a trial fit against the bulk head

[trig]

but

[djwilma]

Well the engine is in the car, gearbox mount is on but the cam cover side of things is a little bit of a bugger

The aluminium mount is touching the plastic cam cover



But as said the engine is in and not too bad a fit







There is a little bit of room for the manifold and turbo to be fitted



When i got home today also had a couple of goodies waiting for me, the ECU DTA S80Pro and the GTX2867 turbo oh and a reminder i only have 8 weeks to finish the car off









This is the compressor curve for the GTX it is supposed to spool a little quicker than a disco potato and flow as well as the GT2871 and stay efficient above 2 bar boost !

[djwilma]

Engine mount was made today, used the existing 620 turbo mount and modded to suit the std elise one

Will see how this gets on as the std mount is not known for its torque holding capability but the vibratechnics ones are

Thanks for comments so far






Also got the bottom engine mount made too

Engines sitting where it should now

Well the turbo and manifold are in

its a little tight but nothing a few bits of heat shield cant help

[trig]

Good job buddy

[cossymax]

That should be a lot of fun when its done, and will upset a few people as well. look forward to seeing this out on track. keep up the good work

[Sonus]

I might have missed it, but are you using the PG1 gearbox from the K-series? If so is the T-series a direct bolt on job?

I need to plan ahead for when my MG ZT 1.8T kills its k-series engine next (done it three times already )

[djwilma]

Trig, it will be ready for a trackday soon so if you do another one make sure you let me know

Cosymax, will do just wanted to keep up with the lotus cortina

Sonus, yes the PG1 was originally fitted to the T series engine, they then changed the bell housing to suit the k series so they are in theory interchangeable. However your 75 Turbo doesnt have a PG1 it uses the IB5 gearbox.

T series in a 75 would be a ball ache, as the weight would upset everything. Best thing to do is sort out the water issues that cause the Head Gaskets to go, easily done when you know how. Then ZandF remapped ecu and 180bhp on std internals

Easy when you know how :P and if you need help i built a 300bhp k series so just pm me.....MGB looks like but i would of gone turbo K from the 75 with a few tweaks and 280bhp

[djwilma]

Couple of bits turned up today

Gaz Gold Pro from junks thank you sir
3" 200 cell cat rated to 400bhp
Vibratechnics engine mounts for k series but using the motorsport harder compound for the engine



Oil cooler is next problem the 620 oil pump doesn't have any tappings for the cooler and they are in the wrong place so looks likely to be a remote filter with cooler attached

Got a couple of extra naca ducts and bought a 4 inch inline fan to circulate air when stationary or higher temps

Also got a turbo blanket as it was cheap

[djwilma]

3 inch down pipe was made yesterday nice tight fit but it's in

[Sonus]

......
Sonus, yes the PG1 was originally fitted to the T series engine, they then changed the bell housing to suit the k series so they are in theory interchangeable. However your 75 Turbo doesnt have a PG1 it uses the IB5 gearbox.

T series in a 75 would be a ball ache, as the weight would upset everything. Best thing to do is sort out the water issues that cause the Head Gaskets to go, easily done when you know how. Then ZandF remapped ecu and 180bhp on std internals

Easy when you know how :P and if you need help i built a 300bhp k series so just pm me.....MGB looks like but i would of gone turbo K from the 75 with a few tweaks and 280bhp

How much is the weight difference between the T and K? Oh and ops on the gearbox :red:

Already have a ZandT ECU to go into the car, just a little apprahencive (spelling?) since I've had two HGF and one turbo failure. However all should be good now so shouldn't be a problem.

I was considered the K-series and M-series in the MGB, but opted for the Zetec for reliability and for the two fingers to the flat cap brigade

[djwilma]

K is a bit temperamental but with a prrt thermostat and oil cooler it will go forever 75 is also a heavy car and once the heads are skimmed they go soft so keep failing.

T is a good 60kg heavier in std form k is 96kg dressed t is 160kg ish but weight is over rear wheels so shouldn't baby a pbeen roblem. Think the t is already fitted to the mgb

[djwilma]

Ok cut the firewall today, actuator needed to go on the otherside so thought it best to cut out the panel for a bit of extra room and also ease of inspection of the turbo as it will be engine out otherwise

Gearbox sits on the same mounts but about 25mm further towards the passenger wheel so the gear linkage needed a little tweak

Vibratechnics mounts are in, spoke with Phil today and he is happy with the way its in. even mentioned the drivers side engine mount is used on the supras and 700lbft so should be ok (y)

But, bought a new toy, its called the S-dash. I am not a fan of lots of gauges in a car, esp when on a mission as its the last thing you look at, i loved my DASH2 in the metro as it had hi-lo alarms but didnt want to change the std stack on the elise to keep the car looking std as possible.

So Drew at Roverdose showed me this S-Dash made by a guy in Belgium. It plugs into the DTA (one of the reasons i bought the dta) and can show 48 channels of information. Basically everything the DTA can see if will show and it has HI-LO alarms that can be configured to rpm, temp etc

So above 12.5 AFR above 6000rpm below 15 AFR below 10% throttle etc

It also has shift lights built in, is a data logger with 8mb memory, can hold 8 maps downloadable in 5 secs and an easy wipe screen incase i get any more excited :wub :up