'Official BWR SC Install Thread' - Page 25 - LotusTalk

exlondoner · 06-23-2009, 11:11 AM

I think we got it Wayne!

Quote:

Originally Posted by waydui

I don't have the diagram in front of me, I'm at work right now. If I had the tool I could explain it in a heartbeat. But let me try to add a little more info.

I have attached a pic of how the mounting tab should look AFTER you have pushed the bushing flush. The pic shows the alternator mounting bolt and spacer tube. This is NOT the special tool.

As I recall, the long bolt went in from the left side of the picture, inboard (towards center of the car). The second part of the tool went into the gap between the 2 mountings tabs (you have to separate the tool into 3 separate parts) and then a nut with washer went on the outer side of the outer tab. You then turned the bolt and it gently "rams" the bushing outwards by pushing the hollow tube against the side of the bushing.

The tool seems a little counterintuitive until you start playing with it.

I actually made a mistake and pushed the upper bushing out, but by reversing the tool, I was able to put it back to its original position.

Regards,
Wayne

exlondoner · 06-23-2009, 12:05 PM

Guys now we're stuck on how to get the alternator through everything to it's location, any ideas??

waydui · 06-23-2009, 12:13 PM

Quote:

Originally Posted by exlondoner

Guys now we're stuck on how to get the alternator through everything to it's location, any ideas??

Are you clam on or clam off?

Please say "clam off" !!!

Regards,
Wayne

exlondoner · 06-23-2009, 12:29 PM

lol clam on

now we've managed to get the alternator through but can't get it to sit besidde the hollow bushing

Quote:

Originally Posted by waydui

Are you clam on or clam off?

Please say "clam off" !!!

Regards,
Wayne

waydui · 06-23-2009, 12:40 PM

Quote:

Originally Posted by exlondoner

lol clam on

now we've managed to get the alternator through but can't get it to sit besidde the hollow bushing

OK, I figured it was clam on. No problem.

I had exactly the same problem with the alternator fitting between the hollow bushing and the outer mounting tab.

I had to use a Dremel tool and grind down the tab surface on the alternator itself. It is the flat surface around the bolt hole. I used a fine grinding stone for about 3-4 minutes and wore enough away to easily slide the alternator into place next to the bushing. The aluminum is soft and grinds away easily.

WARNING: If you do this, put painters tape or other tape over the openings of the alternator so no filings get into the housing and cause a short!!

Whatever you do, don't bang with a hammer.

I also used a bolt on the opposite side of the alternator to help pull the alternator into alignment with the hole. I then removed the "helper" bolt and slid the full-size bolt all the way across. BTW, I did need to put a washer on the long bolt so the lock nut wouldn't hit the belt on the outer side.

Regards,
Wayne

waydui · 06-23-2009, 12:49 PM

Here's a pic to show the set-up.

The long bolt and hollow bushing tend to "droop" making it difficult to get the alternator tab in place. Some patience and a few choice words are useful.

Regards,
Wayne

exlondoner · 06-23-2009, 05:12 PM

Wayne that diagram really helped buddy and I managed to get the alternator bolted. I'm having a little issue with mounting the second bolt on the clam since the heat shield is in the way and there's no way to fit the ratchet. Any suggestions.

I still have yet to cut of the bits from the dipstick tube etc....

waydui · 06-23-2009, 06:04 PM

Quote:

Originally Posted by exlondoner

Wayne that diagram really helped buddy and I managed to get the alternator bolted. I'm having a little issue with mounting the second bolt on the clam since the heat shield is in the way and there's no way to fit the ratchet. Any suggestions.

I still have yet to cut of the bits from the dipstick tube etc....

OK, glad that helped.

I'm not sure which bolt you are talking about since you said you didn't remove the clam. I did have a heat shield issue when I put the clam back on, but if you left it in place I don't know where the problem is.

Let me know which bolt you're talking about.

Another warning about the dipstick. Once you cut the the protrusions off the tube, you'll need to grind them down to smooth the tube out. It takes a while. Ask Cory (Cory1000) who helped me. Took him about an hour to get them smooth and painted.

The crank vent breather tube was a little easier.

If you want to call me as you're going through this I can be reached at 216-496-3840 (cell).

Regards,
Wayne

luxige · 06-24-2009, 12:05 AM

Big "Attaboy!" to Wayne...

exlondoner · 06-26-2009, 12:10 PM

Guy's with those that have done this clam on when did your put the new belt back on (at the end?) and does anyone have a diagram of which pullys it is supposed to wrap around and which way?

Thanks

waydui · 06-26-2009, 12:24 PM

Quote:

Originally Posted by exlondoner

Guy's with those that have done this clam on when did your put the new belt back on (at the end?) and does anyone have a diagram of which pullys it is supposed to wrap around and which way?

Thanks

FWIW, mine was clam off and I installed the belt in the sequence the instructions showed. I would probably do it that way so if there are any issues with the belt (e.g. rubbing on the alternator bolt) you can address those before moving on the next steps.

A diagram did come with the kit showing how to route the new belt. I have it at home and can post it later, unless someone else has it more handy.

You're getting pretty close to being done!

Regards,
Wayne

exlondoner · 06-26-2009, 02:31 PM

Thanks Wayne, I don't see any diagram so I'll wait on that.

Almost there!!

luxige · 06-26-2009, 03:28 PM

I think there is a .bmp file on the CD, separate from the photos.

exlondoner · 06-26-2009, 06:24 PM

ah cool I'll take a look.

Quote:

Originally Posted by luxige

I think there is a .bmp file on the CD, separate from the photos.

waydui · 06-26-2009, 06:39 PM

Here's the diagram from the BWR kit.

Hope this helps.

Regards,
Wayne

exlondoner · 06-26-2009, 07:00 PM

Yep saw it on the CD that looks straightforward.

So progress so far - I have the supercharger in place and need to torque the bolts, I did have obe missing (one washer and nut)...so I'll need to make a trip to Lowes to hopefully pickup those.

Tomorrow I should hopefully be done with the install, still have to send the ECU off to Charlie or PES and find a replacement for the drivers side rear tire which is brand new but got some kind of metal stuck in there

.

Cheers to Wayne/Greg and John (fish taco) thus far!

Quote:

Originally Posted by waydui

Here's the diagram from the BWR kit.

Hope this helps.

Regards,
Wayne

fishtaco · 06-26-2009, 07:33 PM

Mick,
You've inspired me with your install. I forgot a little how much I really love my Lotus. It has its issues, but all are forgiven when I hear that supercharger whine and feel that invisable push forward.

I recently drove a 2001 Boxster S for about 200 miles. I really wanted to hate the car because I thought it was kind of ugly and the interior was really cheap looking. Turns out the motor has a great sound and the car feels very stable at higher speeds. It almost had me...then I drove my Lotus. Made the Boxster feel weak and slow, weak in acceleration and slow to react to my inputs.

You are going to love your new Lotus. Adding a supercharger transforms the car. I look forward to reading your impression.

John

PS Glad to help.

waydui · 06-26-2009, 08:15 PM

Quote:

Originally Posted by fishtaco

Mick,
You've inspired me with your install. I forgot a little how much I really love my Lotus. It has its issues, but all are forgiven when I hear that supercharger whine and feel that invisable push forward.

I recently drove a 2001 Boxster S for about 200 miles. I really wanted to hate the car because I thought it was kind of ugly and the interior was really cheap looking. Turns out the motor has a great sound and the car feels very stable at higher speeds. It almost had me...then I drove my Lotus. Made the Boxster feel weak and slow, weak in acceleration and slow to react to my inputs.

You are going to love your new Lotus. Adding a supercharger transforms the car. I look forward to reading your impression.

John

PS Glad to help.

+1...

It's amazing how the SC changes the character of the car.

For me, it feels almost "scary fast".

It's more raw, more brutish and a lot more fun!!

Regards,
Wayne

exlondoner · 06-27-2009, 10:03 PM

Wayne/John

Sorry guys but am I missing something when wrapping the new included belt around the six pullys as illustrated in the diagram I've still got a bunch of slack?

What am I doing wrong?

Thanks chaps (I know it's late) but I'm almost there

Mick

exlondoner · 06-28-2009, 10:50 AM

ok belt is one, pretty much one man job from the bottom

06-23-2009, 12:49 PM	#486 (permalink)
waydui GR8 SCAPE Join Date: Jun 2005 Location: Kirtland, Ohio Posts: 1,182	More info Here's a pic to show the set-up. The long bolt and hollow bushing tend to "droop" making it difficult to get the alternator tab in place. Some patience and a few choice words are useful. Regards, Wayne Attached Images __________________ _______________________ '05 Elise Magnetic Blue, Black, Touring, Hard Top, Star Shield, Stage II Exhaust, Arqray decat pipe, S2 Front Splitter (UK), Sector 111 Rear Tow Hook, Driving Lights, De-Snorkled, K&N Air Filter, Shift-I System, LSS Dampers & Springs, Sector 111 V-Bar, Schroth Profi II 5 point harness, Exige S Probax seats, 1/4 turn undertray screws, Stealth bulbs, BWR SC with PES tune, Innovative engine mounts, SS brake lines.

06-24-2009, 12:05 AM	#489 (permalink)
luxige luxige Join Date: Jun 2007 Location: MA Posts: 1,187	Big "Attaboy!" to Wayne... __________________ In theory, there is no difference between Theory and Practice. In practice, there is. - Y. Berra

06-26-2009, 03:28 PM	#493 (permalink)
luxige luxige Join Date: Jun 2007 Location: MA Posts: 1,187	I think there is a .bmp file on the CD, separate from the photos. __________________ In theory, there is no difference between Theory and Practice. In practice, there is. - Y. Berra

06-26-2009, 07:33 PM	#497 (permalink)
fishtaco Registered User Join Date: Oct 2006 Location: DC and Central PA Posts: 224	Mick, You've inspired me with your install. I forgot a little how much I really love my Lotus. It has its issues, but all are forgiven when I hear that supercharger whine and feel that invisable push forward. I recently drove a 2001 Boxster S for about 200 miles. I really wanted to hate the car because I thought it was kind of ugly and the interior was really cheap looking. Turns out the motor has a great sound and the car feels very stable at higher speeds. It almost had me...then I drove my Lotus. Made the Boxster feel weak and slow, weak in acceleration and slow to react to my inputs. You are going to love your new Lotus. Adding a supercharger transforms the car. I look forward to reading your impression. John PS Glad to help. __________________ 05 Elise BWR 08 Mazdaspeed3 DD 08 Ducati Hypermotard 06 Honda Ridgeline 51,58,65,69,69,71,74 VWs

06-27-2009, 10:03 PM	#499 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	Belt install Wayne/John Sorry guys but am I missing something when wrapping the new included belt around the six pullys as illustrated in the diagram I've still got a bunch of slack? What am I doing wrong? Thanks chaps (I know it's late) but I'm almost there Mick

06-23-2009, 12:05 PM	#482 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	Guys now we're stuck on how to get the alternator through everything to it's location, any ideas??

06-23-2009, 05:12 PM	#487 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	Wayne that diagram really helped buddy and I managed to get the alternator bolted. I'm having a little issue with mounting the second bolt on the clam since the heat shield is in the way and there's no way to fit the ratchet. Any suggestions. I still have yet to cut of the bits from the dipstick tube etc....

06-26-2009, 12:10 PM	#490 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	Guy's with those that have done this clam on when did your put the new belt back on (at the end?) and does anyone have a diagram of which pullys it is supposed to wrap around and which way? Thanks

06-26-2009, 02:31 PM	#492 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	Thanks Wayne, I don't see any diagram so I'll wait on that. Almost there!!

06-28-2009, 10:50 AM	#500 (permalink)
exlondoner Registered User Join Date: Aug 2007 Location: MD Posts: 175	ok belt is one, pretty much one man job from the bottom

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