[fredkto]

Other end of spectrum from Randy Chase, 4Carl and other experts. First, I am a Lotus Newbie (Aug 07), have lots of hand tools, but no machine shop capabilities and am of average mechanical ability. Working alone.

Remove rear diffuser 15 min
Jacking up car with jack stands/hockey pucks 45 min
first time
- wanted more clearance than Rhino Ramps
Remove stock exhaust 2 hours
- difficult to get off without damaging heat shield
- WD 40 helped
- Much ad hoc leverage required
Remove stock cat 45 min

Note: time spent arranging steady rests/supports to avoid: heat shield damage; dropping of units on my chest; and possible damage to supports.

Install Larini sports cat 8 hours

Note: per other posts, the ball and socket joint between header and sports cat did not fit the same as stock – the “ball” is a little bit bigger. Result is that I could only get one of the stock bolts mated with the header flange with the springs in place. Spent many hours trying solutions: clamping flanges together and several variations on pre-compression of the springs. Nothing worked. Final solution was a longer metric bolt from the local hardware store – went in place easily. Others have reported a solution involving shaving a coil off the springs, but I was leery of this approach. Some have speculated that the joint may be too tight and not allow normal movement, resulting in damage from bumps. My theory, which will be tested when back on road in spring, is that normal expansion/contraction heat cycles, combined with some degree of joint movement over bumps, will ultimately result in proper seating of the ball/socket assembly. More to come on this.

Removal of 07 rear panel 1 hour
Note: due to the “bumpers” on the 07, the Larini SE tips cannot be accommodated. Had to purchase an 06 rear panel.

Cutting heat shield to accommodate SE tips 30 min

Installation of Larini exhaust 4 hours

Note: difficult to get muffler fully onto cat pipe U bend due to interference fit. Tried all sorts of leverage techniques to force fit. Still came up 1/4” short on centering the SE tips. Had to play with two degrees of freedom (ball/socket joint rotation plus muffler rotation to get tips properly aligned.

Attach Euro screens and refit rear panel 2 hours
- working alone from under the car, difficult to align
screws which must go up through the boot floor
Block stock exhaust opening in rear diffuser 2 hours
- pop riveted 0.020” aluminum sheet over opening,
painted flat black to match diffuser
Clean up, tools away, trips to hardware store, 2 hours
etc.
Total 23 hours 15 min

Final commentary. Based upon learnings, could now do task in about 8 hours working alone. My hat is off to those who can do same in a couple of hours. A helper would reduce time significantly further. Hope this helps anyone coming to this cold like me.

fredkto