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 DJ Wilmas 111S S2 Lotus Elise, turbo k seriesModerators: Jump to page : 1 2 3 4 5 6 7 8 9 10 11 12 Now viewing page 11 [25 messages per page] | |
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djwilma |
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 Expert Posts: 2812    Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Ok, so i have done some silly things in my life. Jumped out of a plane naked, woke up on a dance floor dressed in a sumo suit whilst the cleaner was cleaning around me etc etc However i have never been so embarressed as when i just got the call about my engine, seems a distinct lack of oil was the reason for the failure. It had a mere 1lt of oil in the sump, which would explain the "knocking noise" from the engine. Worst still is that the Turbo is pretty much seized solid and as its a roller bearing turbo and looks to be junk ! So a very expensive mistake, simply not checking the oil after an oil leak (return pipe from turbo) and a faulty oil pressure sensor and oil switch (Light on stack doesnt work and ecu display was set to the wrong oil pressure)...... [Censored] shit [Censored] [Censored] Anyway the good news is the new engine should be fitted in the next day or so then a replacement turbo needs to be sourced and fitted. I have bought A new clutch, helix rated to 425lbft, its a 6 paddle so i hope its more than digital A custom Inlet with bigger inlet tracks, 660cc injectors still though (may or may not fit) Placed an order for a 60litre pro alloy fuel tank New pressure switch for oil Then we can wind the bloody thing up and break the 450bhp barrier, i can sleep a happy man as long as the wife doesnt find the receipts I have thoughts of a bigger turbo, EFR Twin scroll but the injectors will need replacing and quite frankly 320bhp was more than the roads needed.........must resist Well the engine is now apart, the pistons and the head are undamaged The turbo is stiff, with no play, so its been shipped to Turbo Dynamics to see if they can repair and upgrade to ceramic bearings Rods have taken the brunt of the lack of oil, NO 2 has spun so the rods are basically junk    Clutch is in its a Helix 2.5 from Grant at GBE, hoping it will cope with the 450lbft torque and wont be too digital  Results on the Turbo are in, and its all good in the hood. Basically needed new bearings and a slight fettle and definite lack of oil issue. Lovely Service from Turbo Dynamics, they even installed their motorsport spec when they re-furbed it. I have no idea why i said yes but the word "motorsport" sounded good. Its basically ceramic bearings which needed replacing anyway. They collected the turbo stripped inspected and had it back within the week and less than half price of a new turbo. Engines back in and partly plumbed in Just going to add a smallish intercooler in the side pod to assist the charge cooler, looking at the data log its highest ever temp was 48C but its never been on track so thought we'd pop one in with a little more ducting as well for cold air. Hopefully be back in action next week.......finally Edited by djwilma 29/8/2014 12:45 PM | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Well I finally got time to collect the car, bit of an epic trip Bournemouth to Carlisle and back in a day about 760miles in total Good news was it gave me time to run the new 2.1 engine in. Was very tight when i pick it up and with wet roads it felt, well horrible. Looks good too. Need to add some heat shield to some pipework but will get this done.  Good news was that the car loosened up on the journey back, it now has a 60litre Pro Alloy tank fitted (although it only took 52 litres, petrol poured out the filler so knew it was full) and it nearly made it back on the one tank ! Engine now revs to 7760rpm according to the log so i need to re-set the limiter to 7500rpm Clutch now holds and although a low pedal it grips well, gear linkage needs some adjustment though Engine now feels lovely, had a little play with a V10 R8 on his way back from the EVO triangle, on low boost, and it was neck and neck, managed to pull up along side in a traffic jam and the driver was a little shocked....as was i..... His comment was this is silly quick and you caught me up. Did mention i had another 120bhp and he just shook his head  Curves arent great to be honest, car has too much wheel spin when turning the boost up. And fueling boost etc werent finalised so these are not adjusted 1.34 Bar boost was 386 @ 6200 rpm  1.45 Bar was 412bhp but wheels were a spinning So will when i get a chance i will get some in car footage and drive by's   | ||
| DotMatrix |
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 Expert Posts: 4458  Location: Jelling, Denmark | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | DotMatrix - 19/10/2014 6:41 AM isn't that the same dyno result you put up twice? other than your air/fuel graph which I think looks to have slope I didn't think it should the other lines looks good I think? Was two identical curves, sorry so here is the 412bhp curve and it looks like it just dies at 6200 rpm but notice the boost also drops off. This is due to wheel spin AFR ratio wasnt final on the runs so dont worry too much about them Engine is happy to pull to 7500rpm, actually hit 7750rpm on my log  Edited by djwilma 23/10/2014 9:31 AM | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Been away for a few weeks so took the car for a spin today in the rain so good time to play about with the traction control. DTA has a a wet / dry setting. Dry is limited to 10% slip, but i can adjust this from the car and this allows the car to slide about to about 10 degrees by cutting up to 75% ignition. Wet is Zero slip etc Wound the boost up to 1.7 bar, 3rd gear and 60mph and put my foot down. Car accelerated hit the maxboost and the ECU cut all the power to the engine Same at 0.7 bar and she just accelerated, albeit slightly slower than in the dry Then i noticed the oil temp, its fitted to the cold side of the water and as i have the EWP it doesnt have a thermostat and was showing 12C  So got home and turned the engine off waited 5 mins, car has a turbo timer that circulates water and turns an engine bay fan on, and the gauge shows this  I think the oil temp sensor is on the cold return so will relocate it to the sump, and if its is running cold will add a thermostat. Put the hard top on and took the worst photo ever  | ||
| ding |
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| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | pretty cold oil you have there  | ||
| munday |
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 Expert Posts: 5629  Location: Letchworth/Basildon | There is no way the oil is being cooled down to 12 degrees C through the oil cooler. I would say either the sensor itself or the wiring to it  I know not many people comment here but im always reading it and turning a little bit green | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Munday the sensor is out of the flow and not reading correctly I will swap it with the pressure sensor End of year at work is manic so had no real time, even managed to turn 40 but still look 28 so all is good Got to the bottom of the alternator belt the lower bracket failed Have re- welded it and will take it to a friends garage in the new year for a proper go as the rear of the alternator isn't braced so will add a bracket in as it flexes  Also got some quali session used ZZRs from Andy at Maidstone Sports Cars was too good a deal to say no and have a spare set of wheels so will try and get a track day organised  | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Having a busy time at work so the failed alternator bracket / belt has taken for ever However i quickly realised the bracket wasnt man enough and the belt had been hitting the cam cover, so we have fabricated a new bracket   Still work in progress, but fitted the alternator yesterday fired it up and it hit a heady 11.9 volts. Best bit was the alternator has no numbers and is an unknown origin. One i purchased for the 620 Ti isnt right so i hope second time around to have the right one Also took the chance to make a few holes to let heat out, as the turbo sits close the bulkhead and high up it has nowhere to exhaust and when stationary i have a fan to circulate air but it just fires it out the drivers side vent, where the air filter is. So this will help I am thinking about some additional vents on the body but i'd like to keep it vent free and std ish looking  | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | I like that you have painted the engine green like old mini engines regarding your cooling holes, couldn't you just remove the three grey plastic "grooves" in each side right next to the holes you made? | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Firstly apologies to the nice fellow that spotted my Elise at Tech1 in Poole and asked for an update. Work and family have meant no time for me to spend on the elise. Finally found the electrical problem the cobra siren had gone open circuit and caused all.sorts of weird problems New alternator is fitted and cars running well Put a new oil temp.sensor into the sump and temps sit nicely at 85c but hit 112c on a spirited run so need to keep an eye. Dash only logs highest data so may just of been a spike.  Was of course on a track at the time Also had a little mod done to the front as only ever got hot air through the vents and as long as I am.moving it's worked well.    | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Couldnt see diddly out of the dipped head lights so swapped for Philips 55w 150+% bulbs and had the very very scratched headlights cleaned. Found lots of primer / paint on the lenses too I can now almost see when driving.........    | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | Have been getting terrible mpg 60 litres and 150 miles which I just put down to the right foot giggles But decided to re calibrate the AFR gauge and it's made a massive difference, thought the fuel gauge was faulty at one point but it's now moving Odometer was zero'd so fairly happy if thats the end result  Next post I am sure will be a i ran out of fuel one Next issue is body work, I have the same problem on both sides a horizontal cracking on the lower section Any idea why     | ||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | It seems the infamous blowing of the main fuse is back Looked at the log and it spiked at 16.9Vs Whats more annoying its its not part of the loom that i have touched, its still the standard elise wiring Popped a new fuse in and meter reads 11.1volts, but the red light is not on. So, the alternator was stripped and inspected No heat damage, no signs of over speeding and the regulator and diode packs are blown. They are connected so.....only a few things that blow these. Heat, overspeeding, bad earth and bad positive So will run an earth from the chassis to the alternator case and see what happens. Decided to tidy some things up, Randy mentioned it once and it's been annoying ever since. The before photo  Added in an Ali plate below the charge cooler so most of the air passes through  I have never had an issue with the Rad always sat high and had a lot of gaps, and the chargecooler rad had gaps behind it so thought about moving thing around.  Reason for this was std fans were installed for the charge cooler, but these restricted flow to the main rad and did little when stationary. So removed these and reset the main rad lower  Next was the charge cooler pump, it used to fly free but added a bracket to the pump. Orientation is terrible.but best we could do  Next was the windscreen wiper, purchased a new motor and fitted it. Same as before, intermittant is 2/3rds of the screen and stops wherever it wants and high speed does nothing. Assume this is the relay so will change that  | ||
| R100_vvc |
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 Expert Posts: 2029 Location: sittingbourne, kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | |||
| R100_vvc |
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Expert Posts: 2029 Location: sittingbourne, kent | |||
| djwilma |
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Expert Posts: 2812 Location: Bournemouth | You seem to forget who I am | ||
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