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MarkKassim

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Posts posted by MarkKassim

  1. Hi Guys,  the charge cooler has changed slightly from the link you have there , its now more compact 

    CC.thumb.JPG.f8966761342839cb4d0e5be2a796f68c.JPG

    It is about 3 time the volume of the original and maintains the same flow layout, so fitting is quite easy. The water hose connections come at the standard size which i think is around 16mm.

    However Alunox can supply with larger ones as shown here at 19mm . I can only speak from my own experience , it did hold up well with new BorgWarner 6258-G turbo on the dyno running higher flow and boost.

    I don't have a photo of the original unit as yet but I will try and get one. The standard unit will be a direct replacement for the original, built to the same dimensions.

    Mark K

     

     

     

     

     

     

  2. Hi Guys, I've been in touch with Ben about another group buy for the Esprit 321 Stainless Steel Manifold if anyone would be interested. The prices Ben posted earlier in this thread are still current.

     These are the details of a group buy if we get the interest

    • 30 units in total - mixed G Car and Stevens 
    • Fitting kit - All gaskets and Stainless nuts included
    • G Car GB price including TurboSmart external wastegate £1650 normal list price £1950
    • Stevens car manifold - £1150 normal list price £1350
    • Rear system G Car 2.5” - £650 normal list price £850
    • Rear System Twin Exit Stevens car 2.5” £600 normal list price £750 - based on min 10 units
    • Rear System Twin Exit Stevens car 3” £780 normal list price £950 based on min 10 units
    • Special requests for T4 flange for turbo upgrade can be included in this GB, I will get the GB price on request

    Also the Charge Coolers can be in a separate group buy

    • Standard charge cooler £500 normal list price £750 - based on min 10 units
    • Uprated charge cooler £700 normal list price £1100 - based on min 10 units

    I will get more info on the standard unit as this is new, I believe it has the same dimensions as the original charge cooler.

    All prices are plus VAT and postage

    If you have an interest in any of the above let me know and I can create a Group Buy thread. For anyone considering the Alunox 321 SS manifold for the first time, they have been around now for about 10 years with no reported failures. 

    Mark

  3. Thanks guys for your great feedback, your comments are much appreciated.

    The transition is unmodified but the clutch is uprated, Dave helped me out with the specification of this putting together some of his old parts. The pressure plate and friction plate are AP capable of holding 330 lb/ft. I may be pushing my look if I go much further with the transmission.

    Mark K

  4. Hi Robin, Yes that is a twin scroll manifold and if you have the normal Alunox manifold it is also a twin scroll as Barry has stated. My particular manifold design has been adapted in the final section (Collector) for the T4 turbo instead of the standard T3.

    This is the size of the T3 Flange vs the T4 Flange

    488975210_T4T32.jpg.1fa1af8900488c784e7d1c16f5e98312.jpg

    Sorry its not the best picture, the Collector design has been enlarged to match the bigger port sizes of the T4 flange. 

    IMG_2870.JPG.a0e57a4ce6d577cf40fb2092ae152c8f.JPG

     

    Hope this helps,

    Mark

    • Like 1
  5. Hi Thomas, Yes it is an expensive dyno that can hold static loads and so tune each speed site or cell in turn.  During part of the video you could hear him holding constant RPMs while he dialled in the speed sites. I think this formed part of the base mapping

    55871919_IgnitionMap.PNG.84202789c735a53fffa72a833dd45883.PNG

    Later on the power runs he tunes the Boost control. I'm not running a Knock sensor so its pretty much tuned under load avoiding detonation (knock), so it may not be as close minimum you are looking for.

    I forgot to mention I am running a wide band lambda sensor and EGT sensor (PLX)

    Just out of interest what ECU are you running.

    Hope the table helps

    Mark

  6. I have now fitted the plenum expansion plate, the install is easy as there is good access.I’ve ran the car hard at Castle Combe at the weekend and noticed it feels like it has more torque at high RPM and delivers it is smoother,  which would be due to the better flow distribution across all four cylinders

    2034517086_Spacer3.thumb.jpg.9a300f67e0205d6325cb03da4dc46075.jpg

    The spacer is made from aluminium and has been machined to follow the contours of the plenum. The bolt holes have small counter sinks for easy location when fitting. The top section is angled to allow better flow into the plenum. The kit includes stainless steel hex head bolts and washers along with a pair of gaskets. The exiting support bar which bolts onto the engine mount can be retained, I offset it at the mount by using an addition nut. Overall it was an  easy mod with a 13mm spanner.

    The Plenum is now available to Pre-Order here on PNM's website:

    http://www.pnmparts.co.uk/lotus-plenum-extension-9090

    It's available as a kit or just the plate, priced at £169.95 + VAT for the plate and an additional £29.95 for the gaskets and bolts (kit) plus delivery. PNM have agreed to give a 15% discount to this group buy which will apply to the plate and kit, I will PM the discount code to the you guys on the list which is valid until the 10th June. The discount is open to another 5 if anyone else is interested. Delivery charges are calculated on the website including shipping overseas.

    Mark K

    • Like 2
  7. Hi Andy,

                  I asked the same question when I upgraded the charge cooler to approximately 3 times the volume. I was told its so small you dont notice it , and after driving with the bigger Charge Cooler I didn't notice any increase in lag. This is only 25mm deep , I've seen on other forums bigger spacers. I hope to have an updater from PNM this week.

    Mark

  8. Hi Chillidoggy , I have a dyno result before and I plan to Dyno again after I fit it. It may be difficult to interpret the results due to my other modifications. I believe it increases VE at higher RPMs. My tuner at Emerald is very good at explaining the Dyno results I will ask him. Dave Changes will have the a lot of dyno info on this.

    Mark K

  9. Hi guys, I’m in the process of ordering a 25mm plenum expansion spacer from PNM engineering, Pete is having these made. It will come as a kit including gaskets and extended bolts. I can’t give an exact price at the moment, but it will be around the £150 + gaskets and bolts, possibly less if we have the numbers. If anybody would be interested in this modification could you add your name to the List. 

    1)      Mark K

  10. Hi Pan, I take it the  V band flange is for the connection of the rear system to the turbo, Leon can help you with that , you will have to send him the dimensions. 

    The difference in the pipe layout is only changed for production , they are still collect in the same order , just 2 overlaps 3 or 3 overlaps 2.

               Hi Franco, for our needs I think the internal wastegate is fine. I know the external units can have better flow ,but they are very expensive and are really used on professional 

    race cars. I know the S3 Esprits use one ,Alunox developed that set-up so it was a direct replacement. 

    After dynoing my car I found I needed the Stiffer spring in the wastegate, as the flow characteristics of the Alunox manifold blew the wastegate open. The medium spring couldn't hold it.

    If you were going for very high power say around 500BHP then maybe go for the external.

    Mark

  11. Stevens Esprit 321 Stainless Steel Manifold Group Buy

    Kit.thumb.jpg.337361732c8557dc9ffb02b721cfc0ef.jpg

    This is Group buy No 5, the 321 Stainless Steel manifold upgrade for the Peter Stevens 4 cylinder Esprit. This is a GB for 10 units which are currently made and in stock so there will be a quick turnaround once 10 people have signed up.

    For those of you who haven’t seen this upgrade before, a recap on the history of the company and the product:

     It was developed by Alunox who are a well-established engineering company that supply the motorsport industry with tailor made high end exhaust systems, made of exotic materials such as Inconel, titanium and 321 Stainless Steel etc. They also supply BAC cars with a full light weight for their current production car the Mono.

    Alunox took on the job of redesigning the original cast manifold for the Esprit due to its failure rate. But also were able to offer uprated performance using their expertise in this area.

    The manifold is constructed from 321 Stainless Steel, precision TIG welded in dedicated jigs giving a fracture proof construction. The flanges are CNC machined out of Stainless Steel to give an accurate fit, the collector uses burns double slip joints to allow movement during the heat cycle whilst being protected against shock loading by the pivoting brace mounted directly above the turbo.

    950004534_BraceRear.jpg.b93a78d2c6b3374d69f83a6e52e3d991.jpg

    The downpipes are all equal length mandrel bent tubes to maximise flow arranged to fit within the space available. Even at normal driving speeds the exhaust gas temperatures are typically 750 to 850 °C and greater during track use. The manifold has been proven to withstand all the temperatures and conditions produced by the Esprit. The manifold is also lighter than the original cast unit weighing only 6 Kg.  All these attributes produce a durable high quality product with gains in both power and torque and lag reduction.
          It has been dyno tested as seen in the video below on a highly modified Esprit running at 424 BHP and 409 lb ft torque. Further gains have been made since the video was made taking the Power to 461 BHP and Torque 450 lb ft.

    Further in-depth technical info on this can be found on Dave Changes thread  

    http://www.thelotusforums.com/forums/topic/55155-exhaust-manifold-design-test-result/

    The manifold is has also been tested with modern twin scroll turbos yielding some great results which I will post soon.

    It has been ran on the track and driven hard without fail. Look for feedback on the forum about performance gains.

    The kit also includes all gaskets, stainless steel nuts and brace. The turbo flange can be changed to accommodate different turbos, as can the collector be made to order. These adjustments are at extra cost and can be discussed with Leon at Alunox.

    The manifold comes with 1 year warranty, this does not cover fitting and shipping.

    The normal one off price is £1350 + VAT.

    The group buy price is £1150 + VAT + Shipping & Packaging, for a 10 off.

    If you want to take advantage of this offer sign up below and I’ll add you to the list.

    Thanks,

                      Mark

    272204888_ALUNOXLOGONewSmall.thumb.png.a9fac5e1631fae694abd7995abfa32a7.png

  12. Hi Guys,

                    Just to let you know Alunox have one complete 321 Stainless Steal system in stock at the moment for the Giugiaro Esprit if any body is interested895953703_GCar.thumb.jpg.f039d25592f58f273b3daaa37a34f1ab.jpg

    This will cure all your problems that you have with the cast unit, it won't crack or warp.

    The kit comes complete with the Turbosmart wastegate ,gaskets , brace and nuts .Ring Anita for details on 01978 8551100.or email [email protected]

    Mark

  13. Hi James, 

                   Yes it wasn't mentioned that in order to take advantage of the High Flow CAT options, they need to be fitted with the headers which are being developed at Alunox at the moment. The headers will do away with existing CATs , I don't have any pictures yet but they will be equal length 28" downpipes constructed from inconel and 321 stainless steel.

    Mark

                    

  14. Hi guys noticed your thread debating the Alunox Noise Compliant Silencer, I live in Wrexham close to Alunox and have their full 321 stainless system on my Esprit. I’ve recently been at Alunox for some work and mentioned your comments and can maybe address some of your queries on price and comparison with other equivalent brands.

    From the outset Alunox were asked to produce a Track compliant system for the Evora / Exige. The silencer system would need to have a track focused design that meets the strict noise requirements while maintaining flow and enhancing performance. It transpires that both quiet and loud modes can be used without any loss in performance.

    Just like to confirm that the tail pipe is optional.

    I don’t think this is a like for like comparison with other brands, so begs the question what are we getting for the extra cost?

    5aa420d826690_Ev400Underside3.thumb.jpg.131ebb705d78e31bd67533ab70c77658.jpg

    The stainless rear system like the Titanium option are a completely different in design to the Larini and 2Bular Silencers. This is a dual pass design uses 76mm pipework that is capable of maintaining flow in both loud and quite modes at high RPM.

    Other manufactures run smaller diameter pipe work and rely on the ECU to open the bypass valve at high RPM.

    The unique hexagonal Silencer shape utilises all the available space in the rear of the car to meet noise levels while running 76mm pipe work. Larger diameter pipe work requires greater sound absorption resulting in bigger silencer configurations.

    Other key performance specifications are

    ·         Middle section pipe diameter of OEM 60mm  - Alunox 63.5 mm

    ·         Internal Perforated tubes silencer construction – Straight though design for maximum flow as used by teams supplied by Alunox as oppose to chambered silencer which house tight turns decrement to  flow  and performance.

    ·         Supercharged - Valve Closed – Max Power, Open sporty note – still below 102 dBs

    ·         Helical Exhaust Valve – as used by Lamborghini, specified with High temperature Materials and components.

    5aa421578d5c4_ExValveV2Crop.jpg.acc2f45949b0b475476e67366342a2d4.jpg

    Alunox uses this valve for the more demanding applications in high end super / hyper car systems running temperatures up to 950 °C.

     

    High flow CAT options available as below

    5aa421d4386f8_LOTUSSC.thumb.jpg.d505a73ce00aafcb8b780788cdcea48b.jpg

    To give you some idea of the sound and operating modes here’s video if the NA system in action

     

     

    The Titanium system again dual pass in design but unlike other brands it is entirely made of Titanium including the Helical Valve, Inconel wire wool for silencer packing.

    So yes it is more expensive but it’s not a like for like comparison.

    If I suggest a group buy of 10 it would give forum members more leverage on price maybe we can close the gap a bit, how many would be interested for the NA / 400 Stainless Steel option. I can propose a combination of two separate systems in one Group Buy.

     

    Mark K

    • Like 2
  15. Hi Guys,

                 The Dual Exit Fits the SE Turbo and S4 / GT3. However you have to shape another hole in the valance on the SE / Shorten the black Trim S4/GT3 for the other side . They are available in 2.5" , 3"  and 3.5"

    2.5" Fitted to GT3

    5a14848b3d461_GT4RearTwinExit.thumb.jpg.3aad268ab22f43791f5e349621234b95.jpg

     

    3" Fitted to an SE

    5a1484a77db76_Stevens3InchTwin.thumb.jpg.25d1ff5008ca9b3ca0c215a149aaa912.jpg

    I have ran the 3" now for about 3 years and on track days with no problems wit brackets or resonance.

     

    Going back to the system shown earlier has 3 silencers its not a CAT. However Alunox do produce a V- Banded 200 Cell CAT 

    5a1486015dd49_06-2017Alunox-014D.thumb.jpg.209b13ae0215d4b82c6bad5a7abef6ee.jpg

    Prices

    All in stainless steel

    single 3” £700

    single 2.5” £550  

     

    twin 2.5 £625

    twin 3” £890

    twin 3.5” system £1250

     

    V-BANDED 200 CELL CAT £350 , can be fitted instead of the 3rd Silencer

     

    all plus vat and shipping

     

    Mark

     

  16. Hi Chris ,

                   Noticed your thread , I've been running the 3" Alunox twin rear system , it complements the manifold. I noticed better throttle response when I after fitting it.5a08aa0e2e9fd_StevensRear3InchTwinExit.thumb.jpg.d2246bfc79d4be95c31c27cf5813b311.jpg

    Its runs at about 100 dB's without the 3 rd silencer and way below with (under 95). I love the sound of the twin exit

    Also 3" single exit available

    5a08aa1e0d723_Standardsideexit.thumb.jpg.0902f781a37817b9ce67ee5e24286044.jpg

    Mark

     

    • Like 1
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