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Esprit V8 project


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Coolio*, Mike. It's starting to look like the business end of a Saturn V rocket.:thumbup: When is the next road test?

*my latest entry in the "mediocre at best, pun of the month" contest

Being second is to be the first of the ones who lose.

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Looks extremely neat Mike.

So then with 1.1 bar and intercooling you must be at least 500+ at the flywheel? What ECU code is planned?

I've always wondered with these intercooler solutions about the effect of the vastly increased intake length and volume. Clearly that is going to add to the turbo lag and the volumetric flow is going to be effected too. Is there any data for this set up? I imagine there is a fine balance between intake and intercooler internal diameter and flow velocity to achieve the rated HP.

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Hi Pete,

For sure there will be an increase in lag, as I am also using larger compressor wheels, but I do not expect the lag to be significant. This system is not that different, in pipe length, to the one I had installed in my GT1 project car. That system was excellent and there was very little in the way of noticeable increase in engine response time. There will also be some pressure drop across the chargecooler, but I´m hoping that these can be offset to some extent by the porting work in the cylinder heads and exhaust manifolds.

It will be very interesting to see how the engine behaves on the dyno. The ECU code will be adapted to suit the engine and I will be using a 3bar MAP, to allow for the elevated boost.

First experiences, however, will come from running the standard hi-torque code with the coolers installed.

Cheers,

Mike S

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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Just a short afternoon in the workshop to finish a few jobs on the car.

Finished installation of the coolers - added almost 7 litres of coolant and that´s all pumping round nicely. Bled out the air and no leaks :thumbsup:

grq4_17d_u6qlh.jpg

Fitted my EGT probe using the EGR port in the LH exhaust manifold

grq4_222_u6qlh.jpg

grq4_12a_u6qlh.jpg

Gauge installed atop the wideband AFR meter

grq4_d66_u6qlh.jpg

Also finally installed the horn switch on the removeable steering wheel ...... beep beep :rolleyes:

grq4_c92_u6qlh.jpg

That´s now pretty much done until the ECU work starts. Just need to install the electronic boost controller, to replace the bleed valve currently fitted.

Cheers,

Mike S

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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  • 1 month later...

Hi Folks,

Slow these last days with a few bits and bobs coming and going

Had another Alpacha baby arrive - not the best time of year for birthin´ babies, but he seems fine

grq4_5cf_u6qlh.jpg

On the project front, finally elected for a single dump valve and equalising pipe set-up between the banks

grq4_fef_u6qlh.jpg

Came across a nice partial set of S350 carbon interior that had to go in together with an alloy dash mask (thanks superdave !)

grq4_7e9_u6qlh.jpg

Adapted the air filter arrangement to take a more direct cold air feed

grq4_e5d_u6qlh.jpg

grq4_6b1_u6qlh.jpg

Got let down by supplier problems at SPA, so I don´t have the intercooler in/out gauge installed.

Car is scheduled for a drive back to Hethel over the weekend, ready for a new windscreen and suspension refresh next week

With a sprinkling of snow here, should be a fun drive ....

grq4_3ca_u6qlh.jpg

More news soon :thumbup:

Cheers,

Mike S

Edited by mike_sekinger

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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Are you popping in on your way over Mike?

88 Esprit NA, 89 Esprit Turbo SE, Evora, Evora S, Evora IPS, Evora S IPS, Evora S IPS SR, Evora 400, Elise S1, Elise S1 111s, Evora GT410 Sport

Evora NA

For forum issues, please contact the Moderators. I will aim to respond to emails/PM's Mon-Fri 9-6 GMT. 

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Hiya Bibs,

Would love to !

I will have to see how the weather affects progress as I have a rendevous in Hethel late afternoon/early evening on Sunday. I may have to leave on Saturday to allow for any minor troubles caused by the snow.

If you are going to be around Sunday mid/late morning, then I´ll keep you posted via mobile.

Cheers,

Mike S

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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We're not far from home all this weekend Mike, would be ace to meet you and see the car :)

88 Esprit NA, 89 Esprit Turbo SE, Evora, Evora S, Evora IPS, Evora S IPS, Evora S IPS SR, Evora 400, Elise S1, Elise S1 111s, Evora GT410 Sport

Evora NA

For forum issues, please contact the Moderators. I will aim to respond to emails/PM's Mon-Fri 9-6 GMT. 

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Thanks Simon,

The single valve is purely as a result of the balance pipe - the one valve will be more than enough to release the moderate boost, so why bother with two.

Cheers,

Mike S

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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Ooopsss..... this is how it looks this morning :thumbdown:

grq4_776_u6qlh.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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Well after a horrendous drive up through France I finally made it to the factory on Sunday afternoon.

grpn_ef2_u6qlh.jpg

Car behaved nicely under the circumstances and did not miss a beat.

Had a devils job getting out of Norwich today, as the Airport was snow-bound until 10am

grpn_3bd_u6qlh.jpg

More news later in the week.

Cheers,

Mike S

Edited by mike_sekinger

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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This was on arrival at Lotus

grpn_1ad_u6qlh.jpg

Update on the job list from the factory:

- new windscreen

- new adjustable platform dampers and new springs - front and rear

- rear radius arm polybush kit

- new front upper ball joints

- both wastegates needed freeing-up and will have the standard spring rate wastegate capsules re-installed

- RH driveshaft oil seals

- ride height and aligment adjustments

Work is progressing nicely :thumbsup:

@Mat - I´d love to pop-in. Let´s see what the weather is doing on the Sunday.

Cheers,

Mike S

Edited by mike_sekinger

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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Mike,

Why take it all the way back to Lotus for those trivial chores? ;)

Well maybe the windscreen I can understand, they are really easy to break, or so I've heard from Johan (glass pros broke his while removing it for the roll cage install).

Travis

Vulcan Grey 89SE

My Lotus Photo and Projects Album

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Small update.

Car collected from Lotus, with the car booked for a Dyno session on the Saturday.

Long story short - there was something very wrong with the new clutch. Definately not seeing its full clamping load and slipping at WOT.

After seriously reducing boost in order to establish a baseline run over the whole rev range, the engine made over 400bhp and 330ft/lb of torque at under 11psi of boost..... not a bad figure for standard boost, but not a result. :thumbdown:

grpn_428_u6qlh.jpg

grpn_fc4_u6qlh.jpg

I got back home this morning after a pretty hairy drive through France.

More news shortly.

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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Mike,

Did you happen to resurface your flywheel??

If so I read in the manual you should also mill down the legs of the clutch housing the same amount as your flywheel to ensure the same clamping forces are kept. I did not as I read this after my cover was already back on , BUT hopefully I will have the trans back off in a couple of months for the 6 speed upgrade and possible new clutch cover/clamping options.

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Hi Dave,

The crazy thing is that all components are new. At the moment, I have no answer to why we didn´t have the full clamping load.

I´ll hopefully get the gearbox off next weekend and be able to have a look.

Cheers,

Mike S

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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As soon as the clutch is out, I should be able to determine what is wrong.

The clutch was still able to cope with over 330ft/lb of torque, which is over 10% more than standard peak torque for the engine. I´ll certainly not be hitting the dyno again until I´m absolutely sure that the coupling is dependable.

Cheers,

Mike S

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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All further updates will be made in my Blog.

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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  • 11 months later...

Almost one year on and we finally got the car back on the dyno today for the follow-up ECU optimisation.

The clutch held firm this time and after 14 runs we managed to get a good result - the engine produced:

Peak boost: 1.1 bar

Power: 507bhp

Torque: 437 lb/ft

Inlet temp: peaking 40deg C

Additional details, images and maybe even the clips will come later - so you should be able to see and hear the action.

The new owner of the car will most likely be considering a crack at 200mph within the next few months (weather permitting).

Nice end to the project for me. smile.png

Cheers,

Mike S

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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