Elise: My process of adding Exige side scoops - LotusTalk

Whiskey · 02-25-2008, 02:15 PM

I have posted questions, looked for threads, and have finally decided to just drill into the side of my car and make the exige side ducts fit my 05' elise. People have said that the ducts would not fit, or that the clam is shaped completely different, but I believe that the process can be done. In fact, I am not even going to remove the current fins and will use them as a mounting point for my upper brackets. Please tell me if this is crazy and mechanically not sound. I figure 3 self tapping screws per screw mount should hold this thing together through any kind of vibration. But I only had a minor in mechanical engineering, so...

First, I purchased 2 exige side ducts, 2 mesh side duct grills, and 2 lower mounting brackets from lotusgarage.com . Lotus Garage - Body: Front & Rear Clamshells & Fixings, Exige
Specifically parts 8,9,21,22,10 and another 10.
Edit: See post #27 of this thread for the diagram

Chuck Risen, mentioned later, helped out and ordered the screws and washers that match the front access panels. Specifically six pieces of parts 5 and 6. Lotus Garage - Front Services Access Panels

Although they weren't delivered within a few days, ordered 2/12 and received on 2/22, I expected some delay on the parts and I was given order status from Lotus Garage. So

to Lotus Garage for clarity and a well packaged box of goodies. Those guys are hard to contact by their website's posted phone number. Email seems to work best.

Attached are pictures of the scoops using blue tape. I was trying to position them correctly before making the big plunge and driving self tapping screws into the clam. I don't have the mesh screens glued in yet. I am going to send the scoops, engine covers, ac, and console off to Chuck Risen once I get things lined up.

Edit: I will be using 1/4" nylon rivets to replace the self tapping screws for the lower bracket. The plastic rivet shown in the pic is to have its head grinded to a "D" shape to save space for the mesh. DO NOT USE SELF TAPPING SCREWS IN FIBERGLASS. Drill holes and uses rivets.

I tried to duplicate the single top bracket from the exige pictures that I have seen. I realized after 2 hours of forming, that individual upper brackets would be easier to align. Those took much less time and I found that both sides should be fabricated together.

andrewgotanelise · 02-25-2008, 02:19 PM

Looks good so far!

MHElise · 02-25-2008, 02:51 PM

You are braver than I!

Looking forward to the finished product pics...

Whiskey · 02-25-2008, 10:50 PM

Attached is the finished lower bracket, during and after install. The second picture shows how you have to slip the back part of the bracket under the fin, and it's finished install position.
Edit: I shaved the leading edge of the rivet head to a "D" shape to give more room for the mesh. The leading edge of the bracket is about 7/16th from edge.

3rd picture. Cut a 6" x 2" piece of carboard, press it along the inner scoop., and get your 1st bend point. Then take the other half, line it with the top of the new side duct and find your other bend point. Replicate with metal. Upper bracket was formed with a vise, rubber hammer, pliers, and my hands. Make both left and right hand pair of brackets at the same time for continuity. Form the whole shape first as a 4" piece then cut in half. 2" wide piece of metal, installed with 3 #8, 3/4", self tapping screws. Cut the lower part of the bracket, as needed, so a speed nut can fit over your hole.

You have to use blue tape to hold any bracket in place prior to making a hole. First tape up the bracket(s), briefly hold up side duct to check alignment, then drill screws through the tape and metal if all points align. Loosen screws to remove underlying tape.

Note, be very careful with self tapping screws. I predrilled smaller holes then only use a drill to screw until they start to move into the thread. After that, use a hand screwdriver to finish tightening.

Chris Mackey · 02-25-2008, 11:01 PM

This image says it all.

knucklehead · 02-25-2008, 11:01 PM

I'm personally not a fan of the scoops, but commend you for being resourceful and coming up with a custom solution. The finished product looks great.

SIIK2NR · 02-25-2008, 11:27 PM

Top bracket not too bad. Bottom bracket not so much. That is going to look really bad IMO viewing the car from a 3/4 angle especially with it blocking the fins.

I see the holes that you are trying to use but why not just cap those and mount the scoops from the edges to the clam? Are you going to mount a bracket for the 3rd hole in the rear of the scoop?

Whiskey · 02-25-2008, 11:45 PM

Quote:

Originally Posted by SIIK2NR

Top bracket not too bad. Bottom bracket not so much. That is going to look really bad IMO viewing the car from a 3/4 angle especially with it blocking the fins.

I see the holes that you are trying to use but why not just cap those and mount the scoops from the edges to the clam? Are you going to mount a bracket for the 3rd hole in the rear of the scoop?

I haven't finished the rear upper brackets. I'll start on my second attempt tomorrow. Tonight was more learning than progress. The fins will be behind the mesh and scoop so I don't think they should be visible. If the fins are an eyesore while being behind the mesh, then they will just have to be cut out. If you unbolt your exige scoops, and I really would like some high-res photos, you'll see that I mounted the lower bracket in the same location (approximate) as the factory lower bracket of the exige. Again, I believe the mesh will hide the fins and the lower bracket. Attached is my reference to the factory brackets for a lotus exige, from the Reverie carbon fiber install manual. http://www.reverie.ltd.uk/en/fitting...outerducts.pdf

SIIK2NR · 02-26-2008, 12:00 AM

Stupid me.... forgot all about the mesh grill. Go with it.. should look nice.

Whiskey · 02-26-2008, 08:55 AM

First fitting.

Whiskey · 02-27-2008, 12:07 PM

Sent my side ducts, center console, cig lighter cover, ac shroud, and engine covers to Chuck Risen today. There will be no more updates till I get everything back from Chuck. I am having everything painted Storm Ti, except for the engine covers, which will be Norfolk Mustard Yellow. Its the orangish yellow color on the badge. I have an idea of what it will look like, but I'll just have to see it when its installed. I can't wait to get these back from Chuck.

See Chuck's thread here FS: Painted Center Console (Plus) . Its under the Parts Market of the forum.

I guess its a good time to install the HID lights.

FVRacer · 02-27-2008, 01:00 PM

What you thought was a scratch was the reflection of the bracket.

IsellLotus · 02-27-2008, 01:15 PM

Quote:

Originally Posted by FVRacer

What you thought was a scratch was the reflection of the bracket.

Nice looks!!

Whiskey · 02-27-2008, 04:04 PM

Oh yeah... the reflection. Thanks.

Anyway, I am still looking at a lot of different exige pictures and noticed that I mounted the lower bracket a few millimeters forward than the exige. There appears to be a small space in front of the mesh grill in this lotuscars.com photo.
I noted in one of the pictures that the tab keeps the mesh flush with the door, but may be wrong. This is odd because the back end lined up, and this is probably because I am keeping the trim. I don't think my color mismatched trim will detract from the look too much.

I am curious as to how I will make a tight interior seal on the duct. Any suggestions?

chuck_risen · 02-28-2008, 09:51 PM

Sorry I have not posted in a bit here. I have some stupid virus that has kept me from doing much of anything all of this week. I only get sick every couple of years or so but when I do I am usually dead to the world for a while.
I have some fasteners here that I was planning on trying that look like they will match the Exige OEM ones. If there is enough interest in this a mold can be made of the final design which would lower the cost of the OEM side scoops. I could also make a fiberglass upper bracket and use the same type of clips as in the OEM version which could eliminated the need for the fins and the rubber molding.
So far Whiskey has done a great job and I plan to help him finish everything up in any way I can. I am sure when it is done it will look great.

Whiskey · 03-25-2008, 08:37 AM

Luckily I was able to catch the FedEx driver today at 8:15 AM to get the parts from Chuck Risen. I missed the delivery by 5 minutes on Saturday and had to wait till Tuesday before they would return.

Opened the well packaged box, and to my surprise the color and quality of Chuck's work that everyone has been talking about is no BS.

I believe he nailed the color that I wanted for the engine covers. I thought they might be off color when I saw them on his post on the forum, but when I viewed them in person, they were spot on. Norfolk Mustard is a funky color to catch on camera. Its supposed to be Lotus's color for their emblem but if you look around your car you will see that the front emblem, wheel caps, and steering wheel badge all are a bit different shades of the yellow almost light orange on the wheels. The dip-stick and other parts of the engine bay have the color so I wanted something that would match. I believe it does the car justice. By the way, the detail in the emblem and lettering is a lot better than pictures indicate. Very precise.

The interior bits and side scoops match Storm Ti. as well. He really cleaned up the tiny little nicks that were on the scoops and the finish looks CLEAN. I also want to thank him for helping me with sourcing washers and bolts for the scoops.
THANK YOU CHUCK!
Here's his link under Parts Market again.
FS: Painted Center Console (Plus)

I need to cut into the passenger side tonight to finish that side of the "scoop project". Until I am finished, here are some pics of the engine covers and the scoops' first painted fitting. There is some wiggle room on the scoops' exact placement before I stick the mesh and pull the screws tight. More description on that procedure later.

Lulu (Italy) · 03-25-2008, 08:55 AM

very nice job.
me too i like exige side scoop.
and in my ELise too i mounted Exige side scoop but in carbon material.
take a look (my Elise is in yellow color in pictures) :

http://www.psqadpdk.com/elise005a.htm

http://www.psqadpdk.com/elise006.htm (last picture).

Max

Whiskey · 03-25-2008, 09:04 AM

Quote:

Originally Posted by Lulu (Italy)

very nice job.
me too i like exige side scoop.
and in my ELise too i mounted Exige side scoop but in carbon material.
take a look (my Elise is in yellow color in pictures) :

http://www.psqadpdk.com/elise005a.htm

http://www.psqadpdk.com/elise006.htm (last picture).

Max

I like your yellow striping on the wheels and the stripe under the scoops as well. Nice styling.

Whiskey · 03-25-2008, 10:15 PM

I am going to have to rethink the form of the rear brackets for the side scoops, so no final install pics tonight. I want to make sure the rear bracket can really hold that duct in place.

At least I finished the interior and engine covers tonight. See my above post for updated pictures. The wires on the ac control and the hazard lights on the center console were a pain to connect. My hand size doesn't allow them to fit in those small spaces too well. Plus, I forgot the center console installation puzzle sequence.

loanshark · 03-25-2008, 10:17 PM

Wow looks great. Seems like a lot of work though. I just went with the CF ReVerie intakes, as I don't like the flat look of the Exige scoop as opposed to the curved of mine, and I don't like the exposed bolts of the Exige scoops.

02-25-2008, 02:15 PM	#1 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	Elise: My process of adding Exige side scoops I have posted questions, looked for threads, and have finally decided to just drill into the side of my car and make the exige side ducts fit my 05' elise. People have said that the ducts would not fit, or that the clam is shaped completely different, but I believe that the process can be done. In fact, I am not even going to remove the current fins and will use them as a mounting point for my upper brackets. Please tell me if this is crazy and mechanically not sound. I figure 3 self tapping screws per screw mount should hold this thing together through any kind of vibration. But I only had a minor in mechanical engineering, so... First, I purchased 2 exige side ducts, 2 mesh side duct grills, and 2 lower mounting brackets from lotusgarage.com . Lotus Garage - Body: Front & Rear Clamshells & Fixings, Exige Specifically parts 8,9,21,22,10 and another 10. Edit: See post #27 of this thread for the diagram Chuck Risen, mentioned later, helped out and ordered the screws and washers that match the front access panels. Specifically six pieces of parts 5 and 6. Lotus Garage - Front Services Access Panels Although they weren't delivered within a few days, ordered 2/12 and received on 2/22, I expected some delay on the parts and I was given order status from Lotus Garage. So to Lotus Garage for clarity and a well packaged box of goodies. Those guys are hard to contact by their website's posted phone number. Email seems to work best. Attached are pictures of the scoops using blue tape. I was trying to position them correctly before making the big plunge and driving self tapping screws into the clam. I don't have the mesh screens glued in yet. I am going to send the scoops, engine covers, ac, and console off to Chuck Risen once I get things lined up. Edit: I will be using 1/4" nylon rivets to replace the self tapping screws for the lower bracket. The plastic rivet shown in the pic is to have its head grinded to a "D" shape to save space for the mesh. DO NOT USE SELF TAPPING SCREWS IN FIBERGLASS. Drill holes and uses rivets. I tried to duplicate the single top bracket from the exige pictures that I have seen. I realized after 2 hours of forming, that individual upper brackets would be easier to align. Those took much less time and I found that both sides should be fabricated together. Attached Images __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 03-21-2009 at 06:45 PM.

02-25-2008, 02:19 PM	#2 (permalink)
andrewgotanelise MMA Fighter Join Date: Apr 2007 Location: Where the drugs are cheap and the girls are easy Posts: 1,208	Looks good so far! __________________ 05 NFB Elise / Katana SC / No Snorkle / 3.2 "10" psi pulley / Stage 1 Exhaust / Decat / Green Filter

02-25-2008, 02:51 PM	#3 (permalink)
MHElise Registered User Join Date: Oct 2005 Location: Lake Norman, NC Posts: 81	You are braver than I! Looking forward to the finished product pics... __________________ ___________________ *2005 - #042* / Chrome Orange / Touring / Dual Oil Coolers / Stage II / Snorkel Delete / Green Filter w/ Velocity Funnel / Sector111 Trunk Bootie**

02-25-2008, 10:50 PM	#4 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	Elise: My process of adding exige side scoops Attached is the finished lower bracket, during and after install. The second picture shows how you have to slip the back part of the bracket under the fin, and it's finished install position. Edit: I shaved the leading edge of the rivet head to a "D" shape to give more room for the mesh. The leading edge of the bracket is about 7/16th from edge. 3rd picture. Cut a 6" x 2" piece of carboard, press it along the inner scoop., and get your 1st bend point. Then take the other half, line it with the top of the new side duct and find your other bend point. Replicate with metal. Upper bracket was formed with a vise, rubber hammer, pliers, and my hands. Make both left and right hand pair of brackets at the same time for continuity. Form the whole shape first as a 4" piece then cut in half. 2" wide piece of metal, installed with 3 #8, 3/4", self tapping screws. Cut the lower part of the bracket, as needed, so a speed nut can fit over your hole. You have to use blue tape to hold any bracket in place prior to making a hole. First tape up the bracket(s), briefly hold up side duct to check alignment, then drill screws through the tape and metal if all points align. Loosen screws to remove underlying tape. Note, be very careful with self tapping screws. I predrilled smaller holes then only use a drill to screw until they start to move into the thread. After that, use a hand screwdriver to finish tightening. Attached Images __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 03-28-2008 at 10:18 AM.

02-25-2008, 11:01 PM	#5 (permalink)
Chris Mackey Registered User Join Date: Jun 2007 Location: Austin, Texas Posts: 2,587	This image says it all. __________________ 2006 Elise, Ardent Red, Black Pack, LSS wheels, shocks and springs. ChuforiaGraffix.com SDD Lives On! SweetDaddyDelicious(at)hotmail(dot)com

02-25-2008, 11:01 PM	#6 (permalink)
knucklehead TWRD & Blip advertising Join Date: Jul 2004 Location: Marina del Rey, CA Posts: 3,835	I'm personally not a fan of the scoops, but commend you for being resourceful and coming up with a custom solution. The finished product looks great. __________________ Jacob Join Lotuscar.ning.com for LA Lotus social events 05 Exise, 2bular 6 inch exhaust. BWR double adjustable Penske shocks, Hypercoil springs, HIDs, BWR front sway bar, Light weight PC680 battery w/BWR brace, BWR Black badges and wheel centers, Custom SCC paint job, SCC OEM Exige mesh kit and Exige rear clam details, LSD, Lotus sport clutch and light weight fly wheel. Sector front splitter. Stebel horn. Multivex Mirrors. Volk CE28 wheels

02-25-2008, 11:27 PM	#7 (permalink)
SIIK2NR Exige 260 Enthusiast Join Date: Mar 2006 Location: Sunny San Diego Posts: 369	Top bracket not too bad. Bottom bracket not so much. That is going to look really bad IMO viewing the car from a 3/4 angle especially with it blocking the fins. I see the holes that you are trying to use but why not just cap those and mount the scoops from the edges to the clam? Are you going to mount a bracket for the 3rd hole in the rear of the scoop?

02-26-2008, 12:00 AM	#9 (permalink)
SIIK2NR Exige 260 Enthusiast Join Date: Mar 2006 Location: Sunny San Diego Posts: 369	Stupid me.... forgot all about the mesh grill. Go with it.. should look nice.

02-26-2008, 08:55 AM	#10 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	First fitting. Attached Images __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 03-28-2008 at 10:18 AM.

02-27-2008, 12:07 PM	#11 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	Sent my side ducts, center console, cig lighter cover, ac shroud, and engine covers to Chuck Risen today. There will be no more updates till I get everything back from Chuck. I am having everything painted Storm Ti, except for the engine covers, which will be Norfolk Mustard Yellow. Its the orangish yellow color on the badge. I have an idea of what it will look like, but I'll just have to see it when its installed. I can't wait to get these back from Chuck. See Chuck's thread here FS: Painted Center Console (Plus) . Its under the Parts Market of the forum. I guess its a good time to install the HID lights. __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 03-28-2008 at 10:18 AM.

02-27-2008, 01:00 PM	#12 (permalink)
FVRacer Registered User Join Date: Jan 2008 Location: Indianapolis, IN Posts: 82	What you thought was a scratch was the reflection of the bracket.

02-27-2008, 04:04 PM	#14 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	Oh yeah... the reflection. Thanks. Anyway, I am still looking at a lot of different exige pictures and noticed that I mounted the lower bracket a few millimeters forward than the exige. There appears to be a small space in front of the mesh grill in this lotuscars.com photo. I noted in one of the pictures that the tab keeps the mesh flush with the door, but may be wrong. This is odd because the back end lined up, and this is probably because I am keeping the trim. I don't think my color mismatched trim will detract from the look too much. I am curious as to how I will make a tight interior seal on the duct. Any suggestions? Attached Images __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \|

02-28-2008, 09:51 PM	#15 (permalink)
chuck_risen Director of Engineering Join Date: Jan 2007 Location: I live in Glen Ellyn IL, a suburb of Chicago. Posts: 922	Sorry I have not posted in a bit here. I have some stupid virus that has kept me from doing much of anything all of this week. I only get sick every couple of years or so but when I do I am usually dead to the world for a while. I have some fasteners here that I was planning on trying that look like they will match the Exige OEM ones. If there is enough interest in this a mold can be made of the final design which would lower the cost of the OEM side scoops. I could also make a fiberglass upper bracket and use the same type of clips as in the OEM version which could eliminated the need for the fins and the rubber molding. So far Whiskey has done a great job and I plan to help him finish everything up in any way I can. I am sure when it is done it will look great.

03-25-2008, 08:37 AM	#16 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	first painted fitting Luckily I was able to catch the FedEx driver today at 8:15 AM to get the parts from Chuck Risen. I missed the delivery by 5 minutes on Saturday and had to wait till Tuesday before they would return. Opened the well packaged box, and to my surprise the color and quality of Chuck's work that everyone has been talking about is no BS. I believe he nailed the color that I wanted for the engine covers. I thought they might be off color when I saw them on his post on the forum, but when I viewed them in person, they were spot on. Norfolk Mustard is a funky color to catch on camera. Its supposed to be Lotus's color for their emblem but if you look around your car you will see that the front emblem, wheel caps, and steering wheel badge all are a bit different shades of the yellow almost light orange on the wheels. The dip-stick and other parts of the engine bay have the color so I wanted something that would match. I believe it does the car justice. By the way, the detail in the emblem and lettering is a lot better than pictures indicate. Very precise. The interior bits and side scoops match Storm Ti. as well. He really cleaned up the tiny little nicks that were on the scoops and the finish looks CLEAN. I also want to thank him for helping me with sourcing washers and bolts for the scoops. THANK YOU CHUCK! Here's his link under Parts Market again. FS: Painted Center Console (Plus) I need to cut into the passenger side tonight to finish that side of the "scoop project". Until I am finished, here are some pics of the engine covers and the scoops' first painted fitting. There is some wiggle room on the scoops' exact placement before I stick the mesh and pull the screws tight. More description on that procedure later. Attached Images __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 04-01-2008 at 07:38 AM.

03-25-2008, 08:55 AM	#17 (permalink)
Lulu (Italy) Registered User Join Date: Jul 2007 Location: Italy - Pesaro Posts: 147	very nice job. me too i like exige side scoop. and in my ELise too i mounted Exige side scoop but in carbon material. take a look (my Elise is in yellow color in pictures) : http://www.psqadpdk.com/elise005a.htm http://www.psqadpdk.com/elise006.htm (last picture). Max

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03-25-2008, 10:15 PM	#19 (permalink)
Whiskey Love is More Join Date: Dec 2007 Location: Athens, Ohio Posts: 199	I am going to have to rethink the form of the rear brackets for the side scoops, so no final install pics tonight. I want to make sure the rear bracket can really hold that duct in place. At least I finished the interior and engine covers tonight. See my above post for updated pictures. The wires on the ac control and the hazard lights on the center console were a pain to connect. My hand size doesn't allow them to fit in those small spaces too well. Plus, I forgot the center console installation puzzle sequence. __________________ Will WTB: Elise Hardtop with Hardware - Storm Ti. (Color Code B121) Please send PM Elise: My process of adding exige side scoops (+ Front Mesh) \| 2005 Lotus Elise : Sport Pack : Biscuit Touring Pack : Storm Ti \| BWR Supercharger \| Exige Side ducts and front mesh \| LETSLA Short Shifter (ordered) \| Last edited by Whiskey : 03-28-2008 at 10:17 AM.

03-25-2008, 10:17 PM	#20 (permalink)
loanshark BANNED Join Date: Jul 2007 Posts: 3,227 Images: 41	Wow looks great. Seems like a lot of work though. I just went with the CF ReVerie intakes, as I don't like the flat look of the Exige scoop as opposed to the curved of mine, and I don't like the exposed bolts of the Exige scoops.