Team Phoenix Esprit - 358cid conversion

[M Blur]

Hi Guys,

As most of the work is being down by a sponsoring workshop and I'm only overseeing then I wont be doing any step by step but I will post up pics routinely.

Finally we have the trans and the Phoenix guys aren't wasting any time.

All dormant wiring in both the engine bay and interior has been removed. Woo Hoo.. no more hazzardous Lotus wiring!

Complete interior strip also done including dash and ancillaries. Dash, seats, harnesses all ready to go back in.. maybe a coat of paint first tho.

Engine has been temporarily in the vehicle for measurement without the gearbox, removal of both exhaust pipes done and shortened. They require to be turned around so the pipes are at the top of the engine instead ofthe bottom. This is required due to the rear sub frame fouling the exhausts and due to the fact that the driveshaft's will not fit in their current position either.

G50-50 end casing has been removed from the gearbox for strip.

I sent the workshop a pdf manual/assembly diagram for the circa 1989 Porsche G50-50 gearbox so they can strip further. The spray bar will require modification if the box needs to be fitted alternatively but the issue is, workshop does not want to damage any material without knowing what the inside of the box looks like. If anything falls out or becomes dislodged as they strip, it could be particularly difficult to find out where it belongs! Will then need to check for a cooler, pump etc.

Firewall has also been removed to create space for the engine and gearbox as expected.

Lots of challenges ahead but it's good to see some sort of light at the end of tunnel and I've every confidence in the guys at the shop.

Lots to do ~ long way to go ~ not so much time to do it in..

Edited October 21, 2007 by M Blur

[Guy W Johnson]

Hi Guys,

As most of the work is being down by a sponsoring workshop and I'm only overseeing then I wont be doing any step by step but I will post up pics routinely.

Finally we have the trans and the Phoenix guys aren't wasting any time.

All dormant wiring in both the engine bay and interior has been removed. Woo Hoo.. no more hazzardous Lotus wiring!

Complete interior strip also done including dash and ancillaries. Dash, seats, harnesses all ready to go back in.. maybe a coat of paint first tho.

Engine has been temporarily in the vehicle for measurement without the gearbox, removal of both exhaust pipes done and shortened. They require to be turned around so the pipes are at the top of the engine instead ofthe bottom. This is required due to the rear sub frame fouling the exhausts and due to the fact that the driveshaft's will not fit in their current position either.

G50-50 end casing has been removed from the gearbox for strip.

I sent the workshop a pdf manual/assembly diagram for the circa 1989 Porsche G50-50 gearbox so they can strip further. The spray bar will require modification if the box needs to be fitted alternatively but the issue is, workshop does not want to damage any material without knowing what the inside of the box looks like. If anything falls out or becomes dislodged as they strip, it could be particularly difficult to find out where it belongs! Will then need to check for a cooler, pump etc.

Firewall has also been removed to create space for the engine and gearbox as expected.

Lots of challenges ahead but it's good to see some sort of light at the end of tunnel and I've every confidence in the guys at the shop.

Lots to do ~ long way to go ~ not so much time to do it in..

Did you have to modify any part of the esprit frame?

Guy

[M Blur]

Hi Guy,

First indication are no but will see how low we can get the assembly and how they line up to the shafts.

I'm running an open tailgate so length of trans is no problem.

Headers were inverted to clear

rear cross mbr has been removed for now

also got to contend with rear cage tubes

and new engine mounts par of the course.. of course..

Jon

Edited February 11, 2007 by M Blur

[Artie]

Hi Guy,

First indication are no but will see how low we can get the assembly and how they line up to the shafts.

I'm running an open tailgate so length of trans is no problem.

Headers were inverted to clear

rear cross mbr has been removed for now

also got to content with rear cage tubes

and new engine mounts par of the course.. of course..

Jon

OMG! That's a lot of work! The roll cage ought to stiffen up the chassis a bit!

Artie

[M Blur]

yes - structure is very stiff with plenty of cross diagonals across floor etc..

Edited February 11, 2007 by M Blur

[wiseraven]

Great stuff, it's about time you had your own thread

Good to see some pics at last. Keep 'em coming.

From your other posts, I'm sure you're on top of it, but from my armchair, it looks like a heck of a lot to do before the start of the season. It'll be good to see it all come together.

Phil

[M Blur]

wait till the pics next weekend Phil.. the Phoenix boys don't hang around... the above represented only 1 wk's work.

[silverfrost]

Jesus thats some sized engine B) cant wait to see what all this comes out like, i feel you may need ear plugs when that baby is started up looks fantastic and a very interesting project good to see you have started your thread, keep us posted and up to date, ill be looking

forward to them,

regards danny

[M Blur]

To recap on the engine.. her it is with the valve covers off:

358cid - 5.86l

Barry Codling, Sab Antonio, Texas

Dart Block

Dart steel cranks

Dart 220 runner heads

6" steel rods

Crane Cams rocker arm

HE + 30 l/w pistons

Ferara low back valves

NASCAR springs

Fly cut piston reliefs

Fluid damper

Internally balanced

Special cam - 620 in 600 ex lift

50 degree duration 286

7400-8300rpm for road circuit use

Champ Pans road circuit competition sump

Stepped sportsman compact headers - 3.5" bore with Moroso sound baffles

Uprated fixers

Shortnose water pump

ancillaries

K&N pancake

2 x Fel-Pro gaskets

MSD Ignition controller

MSD Blaster3 coil pack

MSD NASCAR Distributor

Autolite Plugs (x16) tiny!

Moroso Ultra 40 leads (16mm)

MSD Ignition Pill Modules

[Simon350S]

LOL good to see youve swapped the exhaust manifolds, thought you were gonna have them exiting out the tailgate at first!!!

Looks like its gonna sound great, have to pop to one of your race meets to have a good look and listen!!!!

Simon

[M Blur]

actually they swapped and inverted the sportsman compact headers - we'll prb still look to pull in and down as per an Ultima install as the headers sit high.. not a perfect solution but it saves another

Edited February 12, 2007 by M Blur

[M Blur]

One for Hilly..

Gardner Douglas have a full rod linkage to suit the G50 boxes.. this will give me a classic GT40 style shifter - prb to the right hand side.. it's a real shifter for the long nose trans like mine..

Pics.. thoughts?

pic of trans with rear cover off.. rear rodshift arrangement clearly visible..

GD shift arrangement

and shifter..

Do you this will be the closest starting point Hilly - GD want

[wiseraven]

You could also try Ultima for a quote. Same arrangement G50 box to a sill mounted shift. I'd be surprised if you need to do much more than adjust the rod length and drill a hole or two.

Here's the best pic of the Ultima cockpit I could find on my PC:

Phil

[hilly]

I have seen this one before somewhere.

Looks OK to me, epecially for the price.

However I can't see any reason why you can't modify it to fit your current shifter location, it is only a matter of adding a couple of bends in front of the engine. It is on the righthand side on the Ultima bacause they haven't got the large center tunnel the Esprit has. Having been re-fitting the linkage on mine after getting it powder coated yesterday, there is loads of room for you to mess about with that linkage to get it in the centre.

I would say order it up and when it arrives, have a think about adding a couple of bends in it.

Hilly

[M Blur]

will order tomorrow - GD been great - Ultima didn't want to know.. shows the difference in mentality - I'm sure there was once Ultima woudlhave shown more camaraderie.. as is way cooler having a T70 shifter linkage than an Ultima anyways..

I'll have a think about location Hilly - once used to it - a right hand shifter works great for racing if you're right handed and you can get it nice n close to the wheel position....

[M Blur]

ordered! have gone for bare metal to make changes and then paint once all done... doesn't have tpbe pretty - I'd keep it bare metal if it wasn't for corrosion... might just waxoyl it.

Andy Burrows = top bloke.. tried to sell me a 700bhp LS conversion mind; tho my current engine can give me that if I want it.. over 500bhp it's how it delivers that counts. Main thing in a few season will be to convert to an alloy block.. Brodix etc and swap the internals overs... tho Dart block is strong.. alloy ones a bit softer and more susceptible to heat problems. Will see how the iron block effects weight first.

[hilly]

ordered! have gone for bare metal to make changes and then paint once all done... doesn't have tpbe pretty - I'd keep it bare metal if it wasn't for corrosion... might just waxoyl it.

Cool..........................

[wiseraven]

will order tomorrow - GD been great - Ultima didn't want to know.. shows the difference in mentality - I'm sure there was once Ultima woudlhave shown more camaraderie.. as is way cooler having a T70 shifter linkage than an Ultima anyways..

I'm really surprised at Ultima's attitude. I've always found them really helpful (mind you I was looking to buy a full kit at the time). Are you up against any Ultimas? Perhaps they see you as a threat.

Good to know GD still have the right attitude.

Phil

[M Blur]

Basically - 'you no buy Ultima - we no help you'..

I'm up against everyone Phil - no immediate Ultima candy to scalp but hopeful for the future.. got an aquamist fed 650bhp+ Viper to nail this season tho and a turbo Exige and some RX7s etc. However my first target is completion and getting on track.

Donny on 7th looks unlikley but 3rd June at S'stone should be a go-er.. For 08 loking at various open class sportscars and Gt series etc as well as keep with Time Attack for maybe 2-3 years.

[M Blur]

right next headache (or challenge) - any good fabrication shops in the Uk who can mill me up new strong shafts (I know Hilly can do me the adaptor ends but my race mech says to use gunmetal for the shafts and as wide as poss.

[Simon350S]

Milling and all specialised machine work I can get sorted for you......

Its a company that supplied a number of F1 teams and Lotus themselves......

Quality spot on and good on price 2!!!

Is it just a shaft with spilned ends or are you looking at the u/j s as well, dont think they do the u/j's??

Simon

[M Blur]

Milling and all specialised machine work I can get sorted for you......

Its a company that supplied a number of F1 teams and Lotus themselves......

Quality spot on and good on price 2!!!

Is it just a shaft with spilned ends or are you looking at the u/j s as well, dont think they do the u/j's??

Simon

Cool..

UJs as well Simon but shafts would be a start and then get someone to fab up the adaptors... Hilly!!!

Speaking to Andy Burrows at Gardner Douglas and they have GKN shafts for their various LS monsters using Scorpio CV joints.. they sounded very similar size ot the Lotus.. i.e. blimming narrow..

[M Blur]

right - here is the list of to-do's I can think of - sent to workshop and going through it tomorrow night

modifying the filter and spray bar arrangment on the G50-50 trans

new engine mounts to be measured and made up

Rod shift linkage on order from Gardner Douglas today

Dampers to be stripped off and go back to Leda to be revalved and new spring rates sent up.

Line up engine/trans - measure up new shafts and adaptor plates.

Overhaul brakes, order new pads

Re-fit springs and dampers

Try new wheels for size - boot both sets of alloys

New wiring loom + new dash and locate MSD ignition

Weld in quick release hub and fit steering wheel

Position new Optima battery

New cooling system: rads, header tanks and lines

Strip and check suspension arms and r-joints etc.

Order up new fuel cell (front compartment) and make braided lines

Service extinguisher - relocate to pax compartment?

Fit new front bullet lights - add screw on perpex covers.

Strip rear bumper and fit lucas rear lights + rain led light

Position engine/trans

Fit new rod linkage throught o cabin and adjust for shift pattern

Locate new master cylinders

Fit new OBP pedal box

Fit exhaust pipes to headers + fit Moroso headers

Fit accusump canister

fit oil cooler/pump for trans

Order exhaust wrap and wrap headers

Fix new ally firewall + heat resistant material?

Add second side brace to cage

Fit new aero kit etc inc. front end, undertray, engine cover..

Fabricate Y-bracket to support tailgate to trans mounts. Add brackets to support exhausts.

Fit new seats and harnesses

Dyno session - set up engine, carb etc.

Shakedown test at Knockhill - check suspension, brakes and engine set-up

Revise settings to suit

Send to Auotecnique for paint

Send to Underground Graphics for livery

for budget purposes there may be one or 2 cosmetics that get binned to save some cash - rod linkage, wheels and tyres all came in over budget.

[Simon350S]

The company isw called Abbey Precision in Milton Keynes...

They are going to be doing all the new hubs/adapters and mounting brackets for my new wheels and calipers and making me some alloy bells for the new 330mmx32mm discs when I get them..

I've PM'd his mobile number to you

Simon

[M Blur]

tks Simon how good were his prices.>?

only worry being sourcing the cv joints seperately..