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Pro Alloy V8 Intercooler kits group buy...


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I can help there.  The US spec cars have EGR and SAI fitted for strict emissions control.

This hardware will interfere with the compact installation of the chargecoolers and routing of pipework.   For US owners in States where the emissions are less strenuous, they can remove both EGR and SAI and should be able to install the ProAlloy chargecooler kits.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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The Twin ChargeCooler kit we are producing will work perfectly for the UK spec Esprits. Unfortunately we would simply not be able to offer a kit for the US spec cars to allow room left to run the emissions components as well due to space constraints. These Us cars would either need modifying in a way to make the required room for the kit or remove the emissions equipment which, as mentioned by Mike, always check if this is possible and alowed by your state law. 

As for the images i have promised to add to the page, regarding the engine-side components, finally these will be added today. I had a bit of a battle due ot the file sizes which i wasnt expecting (each image is 24mb in size) so i am reducing this at the moment to be more 'compatible'. 

This will begin to outline the parts included from the back of the vehicle, in which we can then begin chatting about why we require the orignal cast boost pipework for modification here per kit and a better understanding of the routing of this monsterous cooling system.

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Finally! The images are included. I will now be able to 'breakdown' exactly as to why we require the supply of cast boostpipes to us and this can be clearly shown/described with showing images to reference back to.

The first image showing a close-up of the cast section on the N/S boost pipe. From this image you can see as to why we need this original pipe to achieve the severe angle change that Lotus had produced on this part and including the scollop as well shown in the images. This is simply not feasible to replicate as simply building this pipe in low numbers would unfortunately raise the price of the kit by a fair chunk for what would be perceived as only small boost pipe but would actually take hours in labour to re-make. The reason these pipes have to be cut can be explained and to put this in a very simple term, we are effectively adding a cooling solution in-between the original boost pipes to cool the air prior entry to the throttle body. As original/OEM, you will have two boost pipes running from the turbos directly into the throttle body. Now with this kit you would have a small 'HOT SIDE' boost pipe (the half cast and half fabricated pipe) then to chargecooler for charge-air cooling and then finally to the next boost pipe which would now be you 'Cold Side' pipe. These fully fabricated 'cold side' pipes would replace the rest of your original boost pipe and make this redundant as now, a charge cooler unit is a percentage of the original boost pipe circuit, so to speak. Once the charge-air passes through the charge cooler is then used the remaining run of boost pipe to your inlets. 

 

More images are heading there way into this thread shortly as well 😁

CAST section NS boost pipe.jpg

Fabricated 'cold side' pipework.jpg

half cast, half fabricated 'Hot Side' Pipes.jpg

Chargecoolers and CC coolant tank.jpg

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When does it make sense to send the compressor ducts to you Alex.   I will sending a number of sets for usage on specific members kits.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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  • Gold FFM

Thanks for the update and pictures Alex.

Could you clarify how new additions to the list like myself should proceed?

Filip

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I have made many mistakes in my life. Buying a multiple Lotus is not one of them.

 

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@ProAlloy-Alex  Going back a few messages, @Escape Filip, was also wanting to join. 

Not wanting to be a nag, but it`s also fast heading towards 2 week since the last update.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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  • 2 weeks later...

@ProAlloy-Alex  Surely you have some updates for us by now?

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Hi everyone!

Apologies for my absence. I have been out of the office working on Motorsport project sup and coming for next year!

We are currently drawing all parts on CAD to ensure perfect fitment and continuity across the batch. This will also aid in future if we need to build any one-off part from the kit as well. Once these CAd files are completed i will share the screenshots of these as well.

Not a problem with adding further members to the group buy! :) We are building a few extra cores just incase for this reason. Within week 45, we will look to finalise all members details within the Group Buy as momentum is building this end! Once all the Charge cooler units have been completed, we will be working on the front-end parts which will be the remainder of the kits for everyone!

In the meantime, i will ask the Esprit Guru's (you guys!) if you would prefer us to carry on with the original planning of the underside pipework form the Pre-rad to the Chargecooler system to be underside-ran hard pipes which will need to be made in 2-part construction for aid in transport or we can look into making these a Rubber hosing system much like the Lotus Exige Chargecooler system we currently build. this would mean passing through the rubber hoses (2x 19mm I.D coolant hoses) through the bulkhead at the front and routing through a side-seal/side skirt to gain access to the engine bay. We will take the majority vote form the buyers on this one!

I hope that's okay for you..

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1. Mike Sekinger 2 part underbody hard pipes

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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  • Gold FFM

Glad to hear things are moving forward and there's a couple of extra cores for us who joined the list at a later time. 👍

I've already got the pipes installed so don't really need them. But if I had to chose I'd go with hard pipes over rubber as well.

Filip

I have made many mistakes in my life. Buying a multiple Lotus is not one of them.

 

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  • Gold FFM

I will be running hard pipes through the chassis but would have voted for hard pipes too.

Is there an option for one piece hard pipes and either collection or more expensive shipping for those in the UK perhaps?

cheers

-Chris

 

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  • 2 weeks later...

@ProAlloy-Alex  Any updates for us?

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Hello Esprit V8 gentlemen,

I (Christiaan S from NL) would also like to be added to the list of buyers for the V8 double charge cooler system. One question. Does the charge cooling system depend on the radiator? I recently installed an aluminium radiator from Wizard Cooling. Will that be a problem?

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Hi Christiaan,  

There is a separate pre-radiator and coolant circuit for the chargecoolers.  This is typically sitting upfront of the main coolant radiator.

168940130_123322473049630_7222360749334643096_n.jpg.b1142b17df4d1775439374e779eeba09.jpg

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Thank you Mike, I own my Esprit V8 already for a long time but are not as knowledgable as you guys so excuse me for asking but who makes this double radiator and what are the cost of these? Just out of curiosity, why did they decide to make two separate radiators and not just one higher capacity for both systems? Is the coolant running through the charge cooler system not the same coolant running through the original system or is the extra radiator added to just create extra capacity?  

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  • Gold FFM

Hi Chris,

There is a pre-rad included with the Pro Alloy kit and this is installed in addition to your current radiator pack (including air con condensers if you have them). 
 

Don’t worry about asking questions we all do it. 👍
 

cheers

-Chris 

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24 minutes ago, cweeden said:

Hi Chris,

There is a pre-rad included with the Pro Alloy kit and this is installed in addition to your current radiator pack (including air con condensers if you have them). 
 

Don’t worry about asking questions we all do it. 👍
 

cheers

-Chris 

Thanks Chris,

Count me in!

Chris(tiaan)

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  • Gold FFM

The charge cooler heat exchanger looks very similar to my Pro-Alloy prototype.

Getting the air out of the system is a long-winded affair. A bleed point at the top would make it far easier and quicker. The one thing I would change if I could.

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Margate Exotics.

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5 hours ago, Chillidoggy said:

The charge cooler heat exchanger looks very similar to my Pro-Alloy prototype.

Good advice.  I`m going to install a burp-pipe or bleed prior to proper installation.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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On 14/11/2021 at 16:58, cschriks said:

Just out of curiosity, why did they decide to make two separate radiators and not just one higher capacity for both systems? Is the coolant running through the charge cooler system not the same coolant running through the original system or is the extra radiator added to just create extra capacity?  

Thermal dynamics - the engine coolant is circulating once up to temperature at between 83-90deg (maybe even a little higher in certain climates).

If that were running through the chargecoolers it would be heating them up, not cooling the charge.   The coolant temperature of the seperate chargecooler circuit is going to be close to ambient temperature and therefore a good medium to transfer heat out of the compressed charge.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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On 27/10/2021 at 16:15, ProAlloy-Alex said:

Hi everyone!

@ProAlloy-Alex  C'mon Alex.  It`s been practically 3 weeks since the last update.

Please can you share your progress?

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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  • Gold FFM

Hi Alex, @ProAlloy-Alex

It would be great if you could share the status of any progress (or not, any info is better than none), ideally if you have any photos of parts during various stages of manufacture I know that is stuff most people on here would be interested in.

cheers

-Chris

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@ProAlloy-Alex  It has been 1 month since you provided the last update on the chargecooler group buy.    On 24th August you suggested giving weekly progress updates which have never since materialised.   

Don`t you think that it`s time to provide us with an update?.....

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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