Honda Supercharged Elise s1 (exige) rebuild and upgrage

[Ceb123]

My son and Me purchased this lotus Elsie s1 with exige body kit with at Honda k20 supercharged engine and quaif sequential gearbox a few months  ago . After driving it for a while we came across a few issues.

rattle in engine bay

rough shift from first to second gear 

squealing rear brake callipers

not a great paint job someone added protective film to front then I a future repair painted up to the film

Exhaust  extremely loud and very tinny noise.
 

 We plan to rebuild the car  including rebuilding engine and gearbox increasing power  add new link ecu with traction control launch control and flat shift 
tidy up interior graw dash  and recover seats repaint front clam.

 

[Ceb123]

We got the rear clam removed rear subframe and engine and and gearbox out  and cleaned all the creased heat protection of the back of the engine yesterday 

Engine mounts were shot rear gearbox mount  to subframe had ripped a tear in the rear subframe which will need Welding . 
exhaust had no filling and cat was empty leading to very tinny noise 

Rear  Caliper bolts were loose leading to squeaks 

will post of  this week exhaust for ceramic heat coating  callipers  ceramic coating .

arms will be stripped and new bushes and ball joints and  arms anodised coated .

engine sent to  track day performance for rebuild more info on that when engine is stripped.

‘gearbox will be stripped for and checked and chasing cleaned.

 

 

532122681_zip3.zip

[MrP_]

Excellent @Ceb123 - looking forward to this!

[Ceb123]

Thanks mr P 

We  got the garw dash fitted tonight easy fit but will some set up after engine and gearbox refitted . It looks good making it look more modern .  

[MrP_]

The digital dashes do lift the interior, plus stop the need for a billion gauges

What ECU are you running?

[Ceb123]

we are running a Honda sport ecu  but are changing it to link to give us more options .

[Ceb123]

New light weight carper kit fitted . 

[Ceb123]

gearbox  finished casing cleaned. All gears checked had to change 1st and 2nd gears as the dog rings were worn and rounded.

[MrP_]

What’s the rebuild interval on the quaife box ? Is the wear on 1st/2nd just a ‘feature’ you will nee me to manage do you think?

[Ceb123]

It’s around 3000km .we change the oil regularly and check for ant metal. Our 1st and 2nd gear problem was causedb by the previous driver if seq box driven correctly  damaged will be minimal . It needs good sharp changes and flat shift set up correctly .

[Ceb123]

We got the gold heat reflection material added to bulkhead and collected a rear arms from the blaster. Will need to tidy a few welds before getting coating applied. Painted fuel filter brackets and cleaned pipe work .need to order black silicon piping to replace any blue pipes.

Edited February 7, 2021 by Ceb123

[Ceb123]

Rear Brake callipers cleaned and powdered coated . They look sharp .

[Ceb123]

Exhaust arrived back after getting ceramic coating in black . Also welded in new 200cell sports cat.

[cweeden]

On 12/02/2021 at 20:29, Ceb123 said:

Rear Brake callipers cleaned and powdered coated . They look sharp .

I see you didn't fully disassemble the calipers before cleaning and powder coating, did you have to take any special precautions to protect the piston etc?

I was about to take mine apart before realising how difficult that is so this seems like a much better option. 🙂 Did you do the work yourself or send them out? If so who did you use?

cheers

-Chris

[snowrx]

What powder did they use for the high temp caliper application? The garden variety stuff I have on hand flows out at less than 400 degrees F.

[Ceb123]

On 16/02/2021 at 20:35, cweeden said:

I see you didn't fully disassemble the calipers before cleaning and powder coating, did you have to take any special precautions to protect the piston etc?

I was about to take mine apart before realising how difficult that is so this seems like a much better option. 🙂 Did you do the work yourself or send them out? If so who did you use?

cheers

-Chris

The calipers where completely dissembled and new pistons and seals installed after painting. Piston key was got Elsie parts.

On 16/02/2021 at 21:27, snowrx said:

What powder did they use for the high temp caliper application? The garden variety stuff I have on hand flows out at less than 400 degrees F.

not sure what powder coating was used as got a specialist firm to do them. same guy that done the exhaust coating. Was told it would peel or fade .

[Ceb123]

Gor the front clam pulled off and pulled of the stone chip film . At some time the the calm was repainted and they painted up to the film leaving a edge . All going to the paint shop in the few weeks . Will get front cleaned and arms stripped for powder coating .

[Ceb123]

Been  a while  busy with another project engine at engine builders due back in two weeks painted rear subframe today .

 

Complete car was dropped at paint shop . iam looking for a top class finish so a bit of time is being taken to get fibre glass smooth.

[Ceb123]

Engine back from rebuild. Gas flowed head new values with double springs new wonser pistons rods , complete over haul , lightweight flywheel.

Rebuild of super charger new bearings replace seals and oil.