My 300+hp Lotus Elise Project

[Cody D]

Over winter I decided it was time to change some things on my Elise, the car is a blast to drive but from the factory it's not overly fast. I weighed the car in stock form, it was 1910lbs, I would like to get that down to mid 1800's. The car from factory came with 190hp and I wanted over 300.

My first real modification was the exhaust, the stock one is fairly heavy (28lbs) and quiet, I went with the BOE Quarter Stick which weighs (8lbs) and sounds a lot better.

http://img696.imageshack.us/img696/1706/img00883352480.jpg (http://img696.imageshack.us/i/img00883352480.jpg/)

http://img852.imageshack.us/img852/5355/img01043382517.jpg (http://img852.imageshack.us/i/img01043382517.jpg/)

http://img192.imageshack.us/img192/692/img01023420837.jpg (http://img192.imageshack.us/i/img01023420837.jpg/)

http://img690.imageshack.us/img690/6181/img01123464035.jpg (http://img690.imageshack.us/i/img01123464035.jpg/)

http://img638.imageshack.us/img638/1042/img01153481788.jpg (http://img638.imageshack.us/i/img01153481788.jpg/)

[Cody D]

Since it's a mid engined car I wanted to have an easier way of accessing the engine for work so I ordered a clam hinge kit from BOE Fabrication, in a couple of minutes I can have the rear clam completely out of the way. I needed to replace the heavy stock battery (30lbs) with a new one, I bought an Odyssey battery (11lbs) and the clam hinge kit came with all the parts needed for relocation to the engine bay.

http://img813.imageshack.us/img813/1323/img10713980591.jpg (http://img813.imageshack.us/i/img10713980591.jpg/)

I had to pull the interior out in order to remove the rear clam shell.

http://img40.imageshack.us/img40/227/img10324047367.jpg (http://img40.imageshack.us/i/img10324047367.jpg/)

Then the rear engine lid.

http://img215.imageshack.us/img215/4853/img10374087727.jpg (http://img215.imageshack.us/i/img10374087727.jpg/)

Then I was able to remove the rear clam shell.

http://img850.imageshack.us/img850/7614/img10414143673.jpg (http://img850.imageshack.us/i/img10414143673.jpg/)

http://img192.imageshack.us/img192/1937/img10444172006.jpg (http://img192.imageshack.us/i/img10444172006.jpg/)

[captain134]

Cool project. Good work!

[Kloubek]

Just out of curiosity, is the Elise capable of handling a TRD supercharger? If so, I wonder if that is a better route to increase the power as opposed to putting in tiny batteries, etc.

[Cody D]

My garage was quickly getting full of parts.

http://img69.imageshack.us/img69/544/img10584238939.jpg (http://img69.imageshack.us/i/img10584238939.jpg/)

http://img849.imageshack.us/img849/5792/img10614267860.jpg (http://img849.imageshack.us/i/img10614267860.jpg/)

I then got the clam refitted on the new hinges, making sure the clam was aligned properly was the hardest part. Getting used to the movement of the hinges when you are lifting takes some getting used to.

http://img35.imageshack.us/img35/2511/img10734441203.jpg (http://img35.imageshack.us/i/img10734441203.jpg/)

http://img69.imageshack.us/img69/3426/img10784724042.jpg (http://img69.imageshack.us/i/img10784724042.jpg/)

[Cody D]

Originally posted by captain134
Cool project. Good work!

Thanks man.


Originally posted by Kloubek
Just out of curiosity, is the Elise capable of handling a TRD supercharger? If so, I wonder if that is a better route to increase the power as opposed to putting in tiny batteries, etc.

Just wait, I've got more to post. The TRD is not the best way to go, I wanted more than the low to mid 200hp that most get with it.

[Cody D]

Now comes the fun part, I ordered a supercharger kit. It's called the Revolution 310 kit it's made by BOE Fabrication, the same company that made the clam hinge and the exhaust. It is from what I've read the most power you can safely go without opening the engine. I should now have 310hp at the crank.

Yay parts.

http://img849.imageshack.us/img849/7190/img11015032404.jpg (http://img849.imageshack.us/i/img11015032404.jpg/)

Here is the lettering on the new intake manifold.

http://img132.imageshack.us/img132/8642/img11045122969.jpg (http://img132.imageshack.us/i/img11045122969.jpg/)

Lots of parts.

http://img27.imageshack.us/img27/6475/img11055182344.jpg (http://img27.imageshack.us/i/img11055182344.jpg/)

http://img840.imageshack.us/img840/2329/img11065235383.jpg (http://img840.imageshack.us/i/img11065235383.jpg/)

[Unknown303]

Wow, looks good. Want some incar video when this is done.

[Cody D]

Here is the Eaton M62, I love superchargers.

http://img709.imageshack.us/img709/7519/img11075326347.jpg (http://img709.imageshack.us/i/img11075326347.jpg/)

http://img12.imageshack.us/img12/3787/img12455712298.jpg (http://img12.imageshack.us/i/img12455712298.jpg/)

Starting to disassemble the intake, wiring, manifold etc.

http://img215.imageshack.us/img215/5240/img11105488473.jpg (http://img215.imageshack.us/i/img11105488473.jpg/)

http://img847.imageshack.us/img847/7876/img11115552696.jpg (http://img847.imageshack.us/i/img11115552696.jpg/)

I had to strip the wrapping around the wiring for the injectors and COP. The new manifold and supercharger meant I had to route the wiring differently than stock.

http://img691.imageshack.us/img691/3475/img12425692559.jpg (http://img691.imageshack.us/i/img12425692559.jpg/)

[Cody D]

Originally posted by Unknown303
Wow, looks good. Want some incar video when this is done.

I need to find a way to do it without going to jail, haha.

[Toma]

Pretty cool!!

[Twin_Cam_Turbo]

You are building my dream car.

[Toma]

Is the kit intercooled? How much boost? What compression is the car stock? ECU? Water injection?

[Cody D]

The rest of my pictures are all from my cell phone because I was just trying to get it done before the weather got nice.

Mounting the intake manifold and blower was fairly easy, the biggest problems I had was getting the new manifold studs into the head without stripping the threads and fitting the blower where the alternator used to be, there was about a millimeter of room between the relocated alternator and the blower snout.

http://img835.imageshack.us/img835/9568/img12516175025.jpg (http://img835.imageshack.us/i/img12516175025.jpg/)

http://img820.imageshack.us/img820/1527/img12476020254.jpg (http://img820.imageshack.us/i/img12476020254.jpg/)

The kit came with an air to water intercooler setup, the intercooler itself is built into the intake manifold, this little radiator is used to cool the fluid. The two fans are pretty noisy but that's okay.

http://img844.imageshack.us/img844/9036/img12526178688.jpg (http://img844.imageshack.us/i/img12526178688.jpg/)

I had to pressurize both coolant systems when I was done, the engine coolant system I actually just blew into it with the bleed screws open, the intercooler coolant system has a pump to move the coolant, we had to cycle the key for about half an hour letting the air out.

The kit came with everything I needed, new colder plugs, a Walbro 255 fuel pump, new injectors, all the hoses and wires. Taking my time and doing things right I installed it over a month and a half, if I had all the parts and wasn't working I think I could have done it in 2 to 3 days.

The car started up great, besides one little issue with a fuel line that I hadn't secured properly the car has been running awesome. It is way faster than it was, 310hp in a ~1900lb car has a great power to weight ratio.

Here is the first start.

http://www.youtube.com/watch?v=BWtLHb_8TrY

[blackpeople]

Cody everytime i see "clam shell" i giggle a lil.
Car looks awesome man. Keep up the great work. You have to come to race city at least one secret street.:D

[Cody D]

Originally posted by Toma
Pretty cool!!

Thanks, I now need to bring it to you to see how much power I actually have.


Originally posted by Twin_Cam_Turbo
You are building my dream car.

Haha, mine too.


Originally posted by Toma
Is the kit intercooled? How much boost? What compression is the car stock? ECU? Water injection?

This kit is intercooled, you can get a blower kit from them without an intercooler but it has about half the power gain. It's bad but I actually don't know what the boost level is, a boost gauge and a wideband A/F gauge are my next two purchases. The compression is 11.5:1. There were two options, a stand alone or a reflashed factory ECU, I went with the reflash. No water injection, that is a good idea though.

[Cody D]

Originally posted by blackpeople
Cody everytime i see "clam shell" i giggle a lil.
Car looks awesome man. Keep up the great work. You have to come to race city at least one secret street.:D

Haha, I don't know what else to call it. I probably will break down and bring it to secret streets, on the Gtech I got 12.7 @ 112mph, if that's close to accurate I would be happy.

[Cody D]

Here is a picture from BOE that better shows the intercooler.

http://img690.imageshack.us/img690/8333/bottom1tvsweb7231018.jpg (http://img690.imageshack.us/i/bottom1tvsweb7231018.jpg/)

[blackpeople]

Dam that thing should be a lil monster, Can t wait to see it

[Kloubek]

I guess you *did* say you wanted 300hp. Ain't gonna get that out of the 1.8l without forced induction.

Very cool - looking forward to seeing the finished build!

[ercchry]

Originally posted by Cody D


I need to find a way to do it without going to jail, haha.

i have an idea...

http://forums.beyond.ca/st/332127/may-17th-spec-d-and-revwerks-first-collaboration-night/

mike bolt and dave with be there doing video/photos too for some nice outside shots to go with the in car!

[n1zm0]

hoist in the garage, so jealous.

S/C'd Elise, so jealous.

[Cody D]

Originally posted by Kloubek
I guess you *did* say you wanted 300hp. Ain't gonna get that out of the 1.8l without forced induction.

Very cool - looking forward to seeing the finished build!

Thanks, hopefully the dyno shows numbers high enough for me to assume it's 300hp at the crank.


Originally posted by ercchry


i have an idea...

http://forums.beyond.ca/st/332127/may-17th-spec-d-and-revwerks-first-collaboration-night/

mike bolt and dave with be there doing video/photos too for some nice outside shots to go with the in car!

That is very tempting, I just keep thinking I'll fly into a wall or someone will hit me.


Originally posted by n1zm0
hoist in the garage, so jealous.

S/C'd Elise, so jealous.

Thanks, the lift is the greatest tool ever, I couldn't imagine working without one now.

[ercchry]

Originally posted by Cody D


That is very tempting, I just keep thinking I'll fly into a wall or someone will hit me.


as long as you take it easy on the carousel the only thing you will hit is grass :rofl:

we are also going to try to match the cars we send out up so there should be minimum passing... plus, who the hell is catching an elise with 310hp on a road course?! haha

[civic_stylez]

Awesome build Cody! Cant wait to see that beast at coffee and cars this year!!!

[m10-power]

Cool build, you should bring it out to a revworks track day. I built up a friends Exige 240R to over 300hp for 'race the base', very quick car.

[Cody D]

Originally posted by civic_stylez
Awesome build Cody! Cant wait to see that beast at coffee and cars this year!!!

Definitely, I'll try to be there for as many as I can, always something new to look at.


Originally posted by m10-power
Cool build, you should bring it out to a revworks track day. I built up a friends Exige 240R to over 300hp for 'race the base', very quick car.

Was that Steve's? I've met him a couple times. You guys used the Blade 300 kit didn't you?

[tomt64]

Beautiful. Does your M62 have a clutch like the Merc ones?

Cant wait to see it at the track. :thumbsup:

[v2kai]

this is awesome. glad you documented it so the rest of us could drool:drool:

[Errol.]

Originally posted by Cody D

...

That is very tempting, I just keep thinking I'll fly into a wall or someone will hit me.


...
Dont worry, I dont think Fadi is driving :rofl:

I love this car, great build!

[m10-power]

Originally posted by Cody D

Was that Steve's? I've met him a couple times. You guys used the Blade 300 kit didn't you?

Yes it was Steve's car and the Blade kit. Solid kit he drives that car pretty hard.

[Cody D]

Originally posted by tomt64
Beautiful. Does your M62 have a clutch like the Merc ones?

Cant wait to see it at the track. :thumbsup:

Nope, it has a bypass valve though.


Originally posted by v2kai
this is awesome. glad you documented it so the rest of us could drool:drool:

Thanks.


Originally posted by Errol.

Dont worry, I dont think Fadi is driving :rofl:

I love this car, great build!

Haha, this time I'll get ran off the track by an RX-8 and not an S2000.


Originally posted by m10-power


Yes it was Steve's car and the Blade kit. Solid kit he drives that car pretty hard.

Yes he definitely does, haha.

[arian_ma]

Beautiful build man. It's twice as awesome that you're doing all the work yourself.

[Phenix]

Had any problems on things that annoy you yet with the car? or has it be pretty much trouble free?

[Cody D]

Originally posted by arian_ma
Beautiful build man. It's twice as awesome that you're doing all the work yourself.

Thanks, the build wasn't overly hard I would say 6.5 out of 10 for my skill level (backyard mechanic), it was mostly time consuming. The best thing about it I think is that I can diagnose and fix most problems that come up.


Originally posted by Phenix
Had any problems on things that annoy you yet with the car? or has it be pretty much trouble free?

I bought the car expecting to have a bunch of issues since it's a Lotus, however the car has been trouble free, the only money I've put into it is upgrades and regular maintenance.

[Phenix]

Did you buy it used out of the states ? i've thought of picking up one of these for a toy.

[ercchry]

Originally posted by Phenix
Did you buy it used out of the states ? i've thought of picking up one of these for a toy.

unless its an 97-04 esprit or 15 years old you are not going to be able to bring up any lotus from the states unless its track only

[msommers]

I remember you talking about a S/C last summer, glad to see you made the decision!

[Phenix]

Originally posted by ercchry


unless its an 97-04 esprit or 15 years old you are not going to be able to bring up any lotus from the states unless its track only

I thought they dropped that bumper rule?

[ercchry]

Originally posted by Phenix


I thought they dropped that bumper rule?

nothing to do with the bumpers, all to do with lotus price protecting canadian dealers.

[schocker]

Originally posted by Phenix
I thought they dropped that bumper rule?
It is not to do with the bumpers, if you google it, there are many difference between the us and cdn model that make it inadmissible.

Very cool build though, I can image it would be much livelier with all that boost :burnout:

[Phenix]

Originally posted by schocker

It is not to do with the bumpers, if you google it, there are many difference between the us and cdn model that make it inadmissible.



Thanks, did the search, what a shame you can't bring these up.

[Scat E46]

Sweet build. Awaiting more video!

(my fav car on forza is a lightned 500 hp elise LOL) so much fun

[Cody D]

Originally posted by msommers
I remember you talking about a S/C last summer, glad to see you made the decision!

Ya, I have lots more planned but I'll probably wait until next winter.


Originally posted by ercchry
nothing to do with the bumpers, all to do with lotus price protecting canadian dealers.

Hopefully it stays that way or my resale value will drop quick.


Originally posted by schocker
Very cool build though, I can image it would be much livelier with all that boost :burnout:

It's a whole different car, the blower whine alone is worth it for me.

[Cody D]

Originally posted by Scat E46
Sweet build. Awaiting more video!

(my fav car on forza is a lightned 500 hp elise LOL) so much fun

Thanks, I'm a Corvette whore in pretty much every racing game.

[962 kid]

Cool car, should be a lot of fun.

http://img192.imageshack.us/img192/1937/img10444172006.jpg

Brake rotor is on backwards?

[Cody D]

Originally posted by 962 kid
Cool car, should be a lot of fun.

Brake rotor is on backwards?

Thanks. The rotors are on properly, haha.

[m10-power]

Originally posted by Cody D


Thanks. The rotors are on properly, haha.

You sure? Looks to be veins going the wrong way, ie left rotor on right side.

[Cody D]

Originally posted by m10-power
You sure? Looks to be veins going the wrong way, ie left rotor on right side.

After extensive googling it looks like some manufacturers use the same directional vane rotors on both sides of the car, on a street car it apparently doesn't matter. Mercedes also does this.

This is from one of the Lotus guru's:


Don't let the fact that the rotors are "one sided" mess you up. Testing has shown that the direction of the vanes in the rotors shows no measurable difference in the heat capability of one side or the other of the brake rotors. Ascetically they seem wrong, but functionally, they work just fine. Having one rotor for both sides of the car greatly reduces the cost of manufacturing and stocking replacement rotors.

[m10-power]

Originally posted by Cody D


After extensive googling it looks like some manufacturers use the same directional vane rotors on both sides of the car, on a street car it apparently doesn't matter. Mercedes also does this.

This is from one of the Lotus guru's:



Must be an accountant ;)

[Cody D]

Originally posted by m10-power
Must be an accountant ;)

Haha, as a guy who works on Esprits you must know more Lotus cost saving stories like this. Like the Renault transmission :D.

[m10-power]

Originally posted by Cody D


Haha, as a guy who works on Esprits you must know more Lotus cost saving stories like this. Like the Renault transmission :D.

Lol yes, the Esprit is a supercar that the accountants ruined.

[Twin_Cam_Turbo]

Hey man is it true your selling, or is someone putting up fake ads again?

http://calgary.kijiji.ca/c-cars-vehicles-cars-trucks-310hp-Lotus-Elise-W0QQAdIdZ280876526

[Cody D]

Originally posted by Twin_Cam_Turbo
Hey man is it true your selling, or is someone putting up fake ads again?

http://calgary.kijiji.ca/c-cars-vehicles-cars-trucks-310hp-Lotus-Elise-W0QQAdIdZ280876526

Ya, I don't keep vehicles for very long. F355 is calling my name.

[Twin_Cam_Turbo]

Shit I wonder if my dad will loan me $40k lol.