Carbon Fiber Body Recreation Project Exige V6

[El-RGB]

 

As promised, the sound of the freshly prepared Exige Roadster modified down the Southwest Alps of Sichuan. The sound recording was not perfect, but a brief reference of the pops and bangs from the Aerie full titanium exhuast. 😆

Framl

[mayak]

@El-RGB I can't remember whether you also replaced your doors. If not, have you seen those? 😍

https://www.jubu-performance.com/en/shop/part-jubu_carbon_tuere-1733

[El-RGB]

On 30/10/2023 at 16:15, mayak said:

@El-RGB I can't remember whether you also replaced your doors. If not, have you seen those? 😍

https://www.jubu-performance.com/en/shop/part-jubu_carbon_tuere-1733

@mayak I've just purchased the doors from Aerie, but thanks for reminding me to keep up the updates here! 😜

Frank

[mayak]

@El-RGB Oh those look nice! Yes, please keep us up-to-date. I really like your project - it is in fact my favorite out there!

No wing, painted carbon parts - perfect understatement. I might copy some of your style for my Exige if you don't mind 

[El-RGB]

On 06/11/2023 at 17:55, mayak said:

@El-RGB Oh those look nice! Yes, please keep us up-to-date. I really like your project - it is in fact my favorite out there!

No wing, painted carbon parts - perfect understatement. I might copy some of your style for my Exige if you don't mind 

@mayak Thanks mate. I might add a wing to it later. I will try to do something that can be added when on tracks and taking off on the roads.

The new track here is finally finished next month. Will be lots tweaking and moding coming up I assume once the track season begins.

 

I'm surprised that no one really talks about the Emira GT4 just won the Macao GrandPrix GT4 race, taking the pole and second place on the podium!

Frank

[Bibs]

https://www.thelotusforums.com/latest-news/motorsport-news/lotus-emira-gt4-takes-first-and-second-place-in-macau-grand-prix/

^ News and also forum discussion below

[El-RGB]

The new track here is opening next month. Before that, I had the chance to dyno the car.

To my surprise,  Alias23 intake together with Aerie full titanium rocks! She is happily running at 341whp (400hp on motor) with a very smooth power curve. The power should go higher a bit more, due to the power locking at 6.5K rpm because the front wheels aren't moving (common things for Lotus ECU does its thing). I'm still happy as it is now.

 

And for more assurance, I've been looking into this recently reported issue on the rear knuckles. After talking intensively with @Leo Exige, we have the flawed rear knuckles, which it can be cracked at the crucial joints. It acts as a time-bomb on the roads and the tracks. In case anyone owns earlier Exige S V6, please do look into the part numbers as we assumed they can be the following: 

This is the comparison between the flawed knuckle vs the revised version (reported on the facebook Exige group).

 

We assumed the flawed version part number began with letter A. (This is Left hand side, originally came with the car.)

On the Right hand side is a new knuckle that I purchased a year ago (due to my accident hitting the wheel on the curb which was told at the first post on this thread). The new version part number began letter B. (I was not aware of this issue at the time, but the older version was no longer be purchased last year.)

Visually, the left side wall is bit slimmer vs. the newer version. If anyone has more information regarding the knuckles, please do share, as Leo and I might start ordering a new version for his and for my left side.

Frank

 

 

[El-RGB]

Finally the new track in here was completed! Before heading back on track, some mandatory towhooks had to put on:

After some researches, I decided to have my friend to completely redo the front tow hook struct. Now it made up to be completely rust-free, strong and light weight!  Big kudos to my friend who designed and built it in his workshop. 

 

Combination with the Rennline towhook, it looked like a thing of beauty. 🤘

 

The rear towhook was also on. The new Spitfire rear toe links made it on time as well.  The old one had a tiny movement in the ball joint section. The newer version was a bit shorter. According to Gaz, with a different ball joint design, it should be solid and free of any movement acting on the car cornering. Gaz from Spitfire sent over the new version toelink free of charge! The new redone rear louver from Aerie was also here. All the white blemish from the first one was all gone and looked pristine. Applause to both of the respectful brands which stood up for their products!

Frank

 

[Bibs]

Very nicely done, looks perfect! 

[El-RGB]

1 hour ago, Bibs said:

Very nicely done, looks perfect! 

Thanks Bibs.

 

Track time!😈

It was the first all-day practice session opened to the public. There was a crowd and quite a big turn out for Lotus' as well. The Emiras had a great contribution to the number of the group.

 

Of course, the Lotus service vehicle was also on site. Kindly enough, they were helping some other fellows for tire patching. The Lotus was put into the same class with some of the big boys. The fastest car of the day was a heavily modified G82 M4 (the only one with a tire warmer shown in the picture), which was in the open-class.

 

It was a big crowd showed up at around 200 cars in 10 groups for two days. It was pretty much a fun event opened up for joy rides and which about 70% of the drivers were amateurs like myself. The track was a approx. 1.3x.xx min track, but due to it basically all new and very very slippery, there were many spun outs but fortunately no major red flags for the entire event.

 

The Lotus'es (even Emira 2.0) were all put into the GT-b class, which was a class with 992s, 911s and 718s. An one class up was GT-c where GTRs and GT3s. And then the higher ups were open class, where the 1.3x.xx boys were.. Our class winner was proudly taken by an IPS Exige V6 (with Nitrons 3way, Alias intake, full custom exhaust and LSD), which ran 1.40.36, followed by a 911 with 1.40.65  and a 500hp 718 with 1.40.76. The Lotus gang walked home with the 1st place trophy, which was surely the greatest pride and joy in the car community here! 😛

 

Although I had terrible issues for not been able to shift to 3rd (which it ruined my time), I was still faster than all the GT-c GTRs 1.46.97 on that day! It was a blast to finally taking the Exige back on track😂

Frank

 

PS: Jubu clutch, Jubu gearbox oil cooler, LSD, etc. were all paid and on the cargo as we speak. 🤘

 

 

[El-RGB]

From last track sessions, my Exige can't shift into 3rd, hence many parts were ordered immediately. The last few days were like the long waited Christmas gifts unwrapping. 😆 The followings are what I have for this batch of upgrade items:

JUBU single disc clutch kit (3kg lighter than stock)
JUBU gearbox cooler kit (my early model Exige doesn't come with one)
JUBU engine cooling kit
Mfactory ATB LSD
Moroso Oil Baffled Pan
MWR Lift Point Kit
Shift Fork Upgraded Pads

And a few more replacement misc...

First box was from JUBU. All the transactions and email replies from them were excellent, and the parts came in as good as how they were expected.

The Komotec cooler is also a good consideration which it does the job more affectively by air. However, after more researches on a heat exchanger, I choose Jubu's heat exchanger. It cools the oils by transfering the heat to the engine coolant, according to Martin from JUBU, this also help the gearbox get warmed faster on every cold start. This would be very beneficial for my need since I would like it works well for street drivings. Heat exchanger is being used on many other oem's solution as well as Lotus on the Cup cars. I have not yet seen this kit used on other members here, so I will see how it goes in a long run.🤞

 

 

I pick the Single Disc Jubu clutch kit over the Evora 400 stock clutch due to the redesigned flywheel from JUBU. This is a beautiful one peice design which is lighter (3kg overall saving) and should solve the flaw from oem flywheel teeth that protentially can be shattered by its design. Fun thing that I was looking at the more aggressive twin disc system (even lighter than the single disc kit), but as told by the Jubu team, the noise it makes would not be best suitable for street use, so I backed off.

 

Inspecting the organic disc, it is one size bigger than the Exige V6S stock disc, which both are made by AP. I believe it is very likely the same disc as used in Evora 400.

 

The Mfactory LSD and Moroso pan looked nice and legit. Matt from MWR was very helpful for introducing the Mfactory which it was good price saving comparing to a Quaife, and which it should act 100% the same functionalities and lifetime warranty as well. Should there be any weight difference between the two, I bet it should be very minimal.

 

To swap out the plastic ones to the new bronze pads on the shift forks, I saw surprises after opening the box. 😥

My third gears were worn out, and this explained why the third was the issue on the track, but I have yet to find out why It couldn't be shifted into gear in the first place. To make this even more nerve wracking, I was told by the mechanic a number of peices had to be replaced at the same time, where were the 3rd gear itself, the synchro and the fork sleeve (altogether as one gear package if any of them get damaged). 

Of course, I did more studies understanding the MT gearbox. Once the gears had their first grind on the teeth, they will become worsened as time adds up. And this is non reversible by changing new oil or any solution. They had to be changed out for new ones. Thanks to the new learned knowledge on the gearings, I went on Deroure and ordered the fourth gear and the synchro as I saw them had a bit minor wear as well. 😭

All and all, I guess it is part of the "fun" experience for modifying cars. My Exige is now opened up and having peieces laying around the shop, but I appreciate so much for the help from Chris and Gary getting the parts to me, especially running into the situation that Lotus is changing out their computer system, which is making the whole thing more chaotic than it seems.

 

Questions:

During the studies on a colder thermotat, I'm yet to be decided on using JUBU's engine cooling kit, which is a colder themostat + waterpump pulley. There are pros and cons on the colder thermostat. Out of all the researches I found, 2GR runs best on around 180-200 degrees F (82-95 degrees C). Colder thermostat usually use on higher hp motors, but not likely for street applications. Please do share if anyone has some insights on this as I will be installing all the parts soon.

Cheers,

Frank

[Paul_D]

Unless I’m missing something, I don’t really understand the idea of a cooler thermostat. I might be missing something, but my thinking is:
 

During normal use the OEM thermostat will keep the engine at optimum temperature. 
 

But during hard use, the OEM thermostat will be fully open anyway. So the cooling capacity is determined by water flow and radiator size. 
 

So unless the cooler thermostat actually allows more flow then the OEM one once they’re both fully open, it not sure what the benefit is? 
 

To me, all a cooler thermostat will do is make the engine run cooler than is optimal during normal use?

[El-RGB]

19 hours ago, Paul_D said:

Unless I’m missing something, I don’t really understand the idea of a cooler thermostat. I might be missing something, but my thinking is:
 

During normal use the OEM thermostat will keep the engine at optimum temperature. 
 

But during hard use, the OEM thermostat will be fully open anyway. So the cooling capacity is determined by water flow and radiator size. 
 

So unless the cooler thermostat actually allows more flow then the OEM one once they’re both fully open, it not sure what the benefit is? 
 

To me, all a cooler thermostat will do is make the engine run cooler than is optimal during normal use?

Thank you @Paul_D, always enjoyed to read your project as well. May I ask where did you purchase your side skirts from? I love the little end-tip that they go up instead of all flat.

So far the information I gathered are:

1) Colder thermostat opens up sooner, which it could potentially keeps the motor cooler at around 75-80C (given the traffic and outside temp conditions) on the street/hwys.

2) However, it sets a lower start point for the cooling system to work on given conditions (like on cruising), but it makes no difference on track when the engine under full load.

3) More importantly, the 2GR runs best at 85-95C, but not below. Running lower than optimum temp could lead to motor running richer and unburned acids or other craps.

Being an optimist, I want to use a colder thermostat, but logically I just don't see any benefit for using one. 

Frank

[Paul_D]

Hi Frank,

I'm afraid that my side skirts are completely unique. They were home made by somebody (they are carbon fibre skinned rather than pure carbon fibre), who then sold them to me once they sold their car.

Going back to the information you gathered on the thermostat, I agree completely. In my mind it will make the car run cooler than is optimal during normal driving, but not help with cooling on track.

Have you had issues with engine water temperature on track, or is it just a pre-emptive measure? The standard cooling system on my 410 seems to cope perfectly with track use, obviously accounting for the fact that generally a summer track day in the UK will be at an ambient air temperature of less than 30°C generally. You can see from the AIM trace that on my best lap that day the temperature nicely controls between 88 and 84 degrees.

 

[El-RGB]

On 21/03/2024 at 15:50, Paul_D said:

Hi Frank,

I'm afraid that my side skirts are completely unique. They were home made by somebody (they are carbon fibre skinned rather than pure carbon fibre), who then sold them to me once they sold their car.

Going back to the information you gathered on the thermostat, I agree completely. In my mind it will make the car run cooler than is optimal during normal driving, but not help with cooling on track.

Have you had issues with engine water temperature on track, or is it just a pre-emptive measure? The standard cooling system on my 410 seems to cope perfectly with track use, obviously accounting for the fact that generally a summer track day in the UK will be at an ambient air temperature of less than 30°C generally. You can see from the AIM trace that on my best lap that day the temperature nicely controls between 88 and 84 degrees.

 

@Paul_DThanks Paul! What an incredible detailed information sharing, as well as the setup from your AIM log! Awesomeness😱

About the engine coolant temp on tracks, I'm happy to say even early model Exige like mine, with an enlarged radiator, it has been doing a very very well job. Compared to other streets or even some heavy tuner cars, the Exige has a very good cooling system (except the gearbox which mine doesn't come with a cooler). On that, I'm pretty sure that I'm going to bail on this colder thermostat. I don't want to car to take too much longer than it already as for warm ups, and definitely do like the car to run more efficiently on the street with the optimum 85C temp (not below).

 

Some very very interesting things I found:

Out of odds, there was a GR86 in the shop with a broken gearbox, and compare to the Exige EA60 gearbox, they look if not the same but very very identical. So with more digging in to the forumns, I found GRMN Yaris to be the "same" EA6x Aisin gearbox! The GR Yaris owners were taking reference a lot on the Lotus cars and our gearbox for durability comparisons (they were also replacing the forks with the same brass pads). 

Looking at the GR Yaris gear ratio, I can say there wild ideas are happening.😇

Frank 

[El-RGB]

Major updates but nothing for power upgrades.

First off were the new 3rd and 4th gears and the synchros

Guys PLEASE look over your synchros and gears! They took me forever to get, and had all pieces together was a b*tch job to do! If I were to do it again, I would simply do everything I can to protect them and make sure they stay in shape as much as possible. Driving on tracks, it was super easy to grind the third and the fourth gear, which it only took the work of one millionth second. (Especially with the early model horrible oem shifter, it messed me up badly!😥)

Thus, besides driving extremely cautiously, my other mechanic precautions were:
1) Jubu gearbox cooler installed

2) Used oils recommended by Jubu team: Motul 75W140 

3) Installed the brass shift fork paddings

 

After all three installed I had following feedbacks: First, the shifting helped 75%. I done a few sessions testing on track, the shifting issues due to overheating were gone, but I still found the car unable to shift 3rd gear under cerntain conditions: first, when the car was in an angle; second, when the steering wheel wasn't straight. This happend when I was about to upshift while exiting a corner, or downshift while trail braking into a corner. I suspected that it had something to do with the shifting mechanism or the cables misaligned like most Lotuses do that. I will try to mend the shifting adjustment later.

Second part of the updates was also nothing to do with power upgrades, but I found it very important:

1) The oil catch cans. It took me many emails going back and fourth with the Radium team. At last, my mechanic took out a white plastic ball inside the metal can and finally made it work like the way it should be.

Finally the 2GR can breath in without the oil vapors and gunks.

I also retired the ITG with the Proram filter bought from the same man who made the Alias 23 intake.

 

The new baffled oil pan installed, along with the quick shift kit. My mechanics loved them so so much.😂 

 

Last but not least, I got a set of anti-window rattler, also designed and made by another Lotus owner. They helped all the Lotus Elise/Exige S2-S3 windows stopped rattling. If anyone interested, I will look for the link again and share it. And final picture looking under the car belly, all the mods had nothing to do with the power performances, but they do add a lot of blingness looking up!😆

Frank

 

[EldonZ]

I hope you put some heat protection between the exhaust and oil pan. I've wrapped my exhaust and put a piece of insulation on the pan.

Later,
Eldon

 

[El-RGB]

On 07/06/2024 at 21:21, EldonZ said:

I hope you put some heat protection between the exhaust and oil pan. I've wrapped my exhaust and put a piece of insulation on the pan.

Later,
Eldon

 

Hi Eldon @EldonZ thank you for the advice. I've been thinking to do the heat shield wrapping and also oil temperature, pressure and afr sensors; however, some local Lotus owners shared the Exiges did awesome cooling on tracks, which most of the time, the oil temperature wouldn't go over 100c. Most of the time it's around 9xC, so I'm debating if I should do the heat insulation wrapping at this moment, where my coolant temperatue also did very well at 92C on track. 

Frank

[El-RGB]

The updates kept on coming 🤘

After a long consideration between the HPE shifter and the oem exposed shifter, I had my final decision biased toward the oem shifter. Here's why.

 

The HPE shifter was reportedly a bit more precise than the later exposed oem shifter, which found on 350s and forward. The HPE was even cheaper and worked compatible with the existing cables and consoles. Trying to upgrade from the early Exige model shifter to the later exposed mechanism was definitely a waaaay more challenge route. It would be involving a whole lot more parts. Just check out the super long laundry list that I just ordered from Chris at Deruore. 😭 

So why I still picked oem over the HPE? It's simply because I longed for the oem exposed shifter ever since it first launched out. I believed that it could mean something in a couple years later when I looked back, and it was like achieving a personal goal that was set even a few years back. Super big kudos to Alex who kindly sent over his part list at the conversion thread.

 

More kudos to Martin, a great gentleman who sent me the MAF sensor bracket 3D file. To anyone who doesn't know this, Martin designed a bracket that helped the MAF sensor connection to stay in tack, which a lot of Exige would have this problem when upgrading to an aftermarket intake system. I can't wait to have this newly printed bracket on! Nice work Martin!

 

I had just received another revised version titanium Y-pipe from Aerie! If anyone had seen posts related to this y-pipe having problem at the joint, where my old y-pipe had the same issue (a hairline crack, which I had the mechanic to re-weld this area). Jason @Jasonf from Aerie was extremely responsible for this, he sent over a newly redesigned version where he had all the spots that can potentially had problems and reinforced with stronger welds and thicker materials! I'm so glad to see this arriving at my door when he surprised me with this new package! What this brand can do is carrying so much confidence to his customers, and to shop at his brand again. I'd recommend to all other friends and Lotus owners.

 

To prevent any potential issue on the titanium exhaust, I also did one step ahead which I hired a local shop and custom made a full titanium O2 sensor extension connector! It took me almost a month to buy the raw titanium materials. By remeasured the dimensions, the shop helped me custom made these two connectors! I'm so happy to see how they turned out and the fitments were perfect. They were so so much lighter than those stainless steel ones that sold on the market.

My primary goal to have these titanium connectors made was because to shed off the weight placed on the exhaust, which during high loads and heats from the engine, it could torn apart the titanium walls on the exhaust. I've seen oem titanium exhaust had some similar issues. However, when the connectors were made into the same material as the exhaust, their reactions to the heat became the same, so by physics they should work better in expanding at the same rate, and ultimately it should make the exhaust last longer! Fingers crossed. 🤞

 

I learned that titanium isn't the optimum material for exhaust systems, but the sound it made the Exige sang, I just loved it so much! Here's a video some friends recorded on the track, which they were all amazed by how this exhaust can make the 2GR motor roared through the bends.

Frank

[Bibs]

That does look and sound amazing!! 

[El-RGB]

I can still not believe this, last Sunday we hosted the probably largest Lotus owner organized event in the country. It had a great turn out, which we had over twenty Lotus attended, and this was the first ever track day event that we hosted it as an one-make Lotus enthusiast event. It was awesome!

I felt deeply blessed, it was 5 years ago that my Exige was in pieces during the accident (told in the beginning of this project thread). Now she did not just resurrected, but also became the reason that led to this first ever largest private event in the country. I felt that this project build thread somehow had fulfiled a purpose, and the efforts spent on her became worthy for the past 2 years.

Cheers,

Frank

[El-RGB]

Seeing some super awesome news after hosting event last month:

Don't know how to put it in words, but fully packed with joy finally seeing this in person.

Almost two years and counting for collecting all these pieces...

I can look at it all day on my work desk. 😆

 

Huge kudos to Chris from Bell and Colvill (Deroure) consistently on the emails and helped on getting those NIL parts.

To those who didn't own earlier Exige V6 models, it's rather difficult to understand it. After years of driving the car, this means no more worrying on original shifter plastic blue-ball joint failing, and finally the best of the shifting motion from factory.

Frank 

[El-RGB]

Still haven't got a chance to install the new shifter assembly, but further detail improvements had pushed forward.

After many small and big upgrades, it was quite a long journey enhancing bits and bites on the Exige like new gears, Jubu clutch kit and gearbox cooler, Spitfire suspension linkages, LSD, etc. As for now, it's such a blast driving the true track prepared Exige around the circuits.

I been through many stumble moments on the aftermarket parts, but the reputable brands stood for their quality and service, such as Spitfire, Radium, Aerie and more responded to my inquiries. They were always there to exchange information and help resolving them.

Among all mods, the Aerie titanium exhaust was one of the earliest parts on the list, and probably the most favorable ones I should say. Namely, the sound truly transformed the car compared to the oem exhaust.

Having it for almost two years which over 20,000 kms and 16 track events, @Jasonf from Aerie has been always there responding to my inquiries and even some revisions followed up after. Again, it's great to have brands such as Jason working on Lotus, which we are already a small ground in comparisons to other cars. Recently I made another tweak to the system which making it even more solid for tracking the system.

This clamp has a tendency to unclamp itself under high heats and loads when driving hard after a few laps on track.

In the aftermath of careful examinations after each track session, my mechanic probably found the core issue was the M8x1.5 steel nut. The nuts that came with clamp could not stand the heat coming from the titanium material (which it is a way more higher energy transfer material than stainless steel). The nuts especially at the Y-pipe session will burn itself and eventually release itself from the bolt, then caused the pipe to loose up completely under high loads.

At the connection where the Y-pie joined with the elbow section (the third cat) was the area where all the pipes merged into one. It was our understanding that this little L-joint continuously taking the most brutal force out of the entire exhaust system, where the exhaust gas got out from the engine, it first moved onto headers, then to the Y-pipe and finally all merged into this tiny single piping.

A R&D experiment was carried out by exchanging the nuts to high-heat resistanding Benz W204 C63 oem turbo outlet nuts, and the result was pleasing! The area where it tends to be problematic is now further reinforced with the heat-resistant nut which doesn't loose up by itself anymore.

Believe it or not, I did careful researches and found out even Lotus oem suffered the same issue at the elbow pipe released itself from the oem Y-pipe. Maybe due to the nature of the Exige's backend had such a compact room, this area had to go with Y-to-single joint at this area, but this slid-on design at this area had to do further reinforcement to take on the brutal force. 

This can also be the area where many Aerie users reported that the system had problematic issues. I'd like to report in, after all the years of having this exhaust on my car, it required above stated knowledge for taking care the system, and it required professionals for careful installation and removals, which means a must for matching the slid-on joints while working on the titanium pipes. 

As Jason also stated before I purchase the system, the system required profession cares and not recommended for ones working on themselves without necessary tools and knowledge on the titanium materials. The pipes MUST remain perfect "circle" shape at each pipe ends before installation, or you will ask for a chance of trouble. (Don't ask how did I know this....)

This retired Y-pipe was the first version from Aerie, which I had the mechanic welded a new hanger on top, which Aerie had incomplemented into their second version. Hurray for brands taking users' feedback.

My old elbow was trashed due to my previous mechanic had a misunderstanding on the system and rushed in on the removal. The miscare of the pipe tip damage will cause the issue to become worse as the driving continues, because it WILL lose itself up under hard drivings, and ultimately trash the system entirely! Thus, the titanium exhaust must require special care working on it (preferably profession shop with proper tools and knowledge on such exhaust), in disregard of oem or aftermarket brands.

Furthermore, I had lowered the front camber from -3.2 to now -2.4 degrees to better use the front tires suitable on the local Tianfu track.

However, recently the steering wheel delivered a "click" on slow speed turning. I tightened the front tie-rods (as shown in the picture), and the symptom became lesser but still exist. Does anyone shared similar experiences?

Cheers,

Frank