Elise: My process of adding Exige side scoops

[climb4fun]

There is no such thing as "touring wheels" or "touring suspension"!!

There are many Elise talkers who have received thwacks for this mistake. Still some do. Ask Tim Taylor if you don't believe me.

[FLuXeXigeS]

touring was used to make the word BASE disappear ... LOL

Base
Lotus Sport
Cup Car
and that is ittttttttt!!!!

[jlj3394]

Just an FYI, we also have scoops. I am getting a lot of micro pitting around the entrances. It won't clay off. I believe there is a suction effect around there that is doing this.
<a href="http://smg.photobucket.com/albums/v649/jlj3394/lotus/?action=view&current=IMG_2528.jpg" target="_blank"><img src="http://img.photobucket.com/albums/v649/jlj3394/lotus/IMG_2528.jpg" border="0" alt="Photobucket"></a>
<a href="http://smg.photobucket.com/albums/v649/jlj3394/lotus/?action=view&current=IMG_2518.jpg" target="_blank"><img src="http://img.photobucket.com/albums/v649/jlj3394/lotus/IMG_2518.jpg" border="0" alt="Photobucket"></a>

[Whiskey]

Originally Posted by jlj3394

Just an FYI, we also have scoops. I am getting a lot of micro pitting around the entrances. It won't clay off. I believe there is a suction effect around there that is doing this.

I am looking for 3M clear shield installer near my home. I heard these side ducts take a beating.

[FLuXeXigeS]

those scoops look great even on the Elise

great job!!!

[jlj3394]

Originally Posted by Whiskey

How was your car delivered on 4/1/08 when its 3/26/08. Unless you are speaking of 4th of January, 2008. Nevermind.



I am looking for 3M clear shield installer near my home. I heard these side ducts take a beating.

Let me be clear, not only are the scoops taking a beating, but the door near them is as well.

[Whiskey]

Originally Posted by jlj3394

Let me be clear, not only are the scoops taking a beating, but the door near them is as well.

Do you think rocks are reflecting off the mesh toward the door? Why hasn't anyone come up with a wider mud flap or a "door hinge cover", #4 on the lotusgarage.com diagram, that flares out a bit more?

[Whiskey]

OK... I've loaded this thread with pictures, but I am trying to show all the things that I wanted to know prior to this project.

So what have I learned?

Exige side ducts can fit the Elise, but don't think it will look identical to the Exige. The Exige doesn't have the thin black trim along the top of the duct. It will be visible and is needed IMHO to fill the space perfectly. Actually, I was surprised about how well it lined up. This may be a factor for those with brightly colored cars or to purist. But look at my brackets. What purist would ever put these monstrosities on a car? They are now covered by a nice skin as far as I'm concerned. I'll clean them a bit and paint them a matte black for some protection, never to be seen again.

Use blue tape to hold any bracket in place prior to cutting into your car. Start with the lower bracket, then top forward. The aft bracket will require patience due to odd bend angles. The first angle is critical.

Only cut a hole in a bracket after it has been mounted. When you believe you have the right bends and its visible through the duct's hole when mounted, then mark the bracket with ink. Complete a "mount and drill" of each bracket, one at a time. Always have the mesh taped to the duct during fitting.

Building the second duct's, or right scoop's, brackets was a breeze. Forget about matching the left side perfectly as I worried about. Worry about how pretty the bracket looks later. Just measure and whack the metal in a vise to create two bends. Create the first bend coming from the car. The second bend is to give a surface to press against when screwing everything down. Contort the metal until it almost matches the form of the inside of the duct. BTW, the top forward bracket should be placed a hair short of an inch back from the leading edge so the mesh can fit properly. Don't put it too far back, you will find that the top of the mesh can use it as a support.

Weather-strip is your friend. It creates a wonderfully soft contact point, as well as a seal for the tiny inner gaps. The foam seal will help keep a nice contact between the duct and the body. I used 5/16" thick x 3/4" wide x 10' from Autozone. The width allows for a nice amount of overhang and you can feel the exposed sticky side grab the duct as you position the duct from aft to front. Its easier to cut several segments instead of aligning one long piece.

Gorilla glue is nasty, ugly, hard core bonding material that needs to be painted or covered. (i haven't cleaned it up yet) The inside of the scoop has "the cream" of the gorilla glue on full display if you were to look from inside the car. It should hold the mesh quite well because the mesh also gets support from the side of the lower and upper bracket. I drove this afternoon with only blue tape holding the mesh against the fiberglass duct. There is plenty of other support.

Be committed to holes, align, and just go. Brackets can be bent for small corrections unlike tattoos. Although, it felt like I was giving my car a tattoo when i drill the lower holes. And what have I really "destroyed"? Well, a set of fins have 5 small holes on the underside. That's a $140 total replacement, if one were to really bother. Three 1/4" holes on each side of the clam. Some puddy in the small holes and a dab of touch up paint would probably hide it well enough that only people that read this thread would even know.

The thoughts of this project started only 6 days after I purchased my Elise. (purchased 12/28/07) Give a month or so of searching for detailed pics of the inside of the Exige ducts and many failed uses of the "SEARCH" button. Then 10 days on parts delivery. Sent the interior, engine covers, and ducts to Chuck on 2/29/08. Chuck ordered bolts, washers, speed nuts, and prepped and painted everything. Received a full package of parts back on 3/22/08. I installed it all during two evenings and upon completion I drove in last night's mild weather with the top off. Today, just a big ol' smile.

Thanks to LotusGarage.com for making the diagrams and a detailed parts list available.
Thanks again to Chuck Risen. His work was awesome.

[Whiskey]

more pics... Hopefully, I get some outdoor shots in the sunshine in the next few days. All my photos have been on a tripod without flash or hand held with a flash. That is why the colors vary greatly.
The gorilla glue really takes away any option of removing the mesh cleanly at a later date. Another adhesive would be preferred. I am going to mask the mess with a wide black tape.
Also, the fit of the mesh against the clam, ref. to the second picture with the door open, doesn't appear as separated in person.
Edit: Slight bend of the bracket and its pulled in closer.

I am in the middle of a seemingly never ending project at work and its nice to complete a side task in full.

[chuck_risen]

Looks awesome Will. I am glad you have the project finished. A big hats off to you for undertaking a project like this as there were plenty of unknowns. It was a pleasure working with you and let me know if you ever get another idea as it was a lot of fun. As for the finished product I think the results speak for them self. The install looks very clean and will probably be mistaken as factory from a lot of people that do not know the car. With the exception of the one upper bracket you made the scoops are all genuine Lotus parts down to the hardware which is a nice touch. I am still amazed on how well the lines match up. Congratulations and enjoy!

[Gideon]

great job Will! Looks much cleaner than my install. I actually took the fins out completely and used two of the existing bolts to fasten the brackets I made for the top and rear scoop allen bolts. The bottom fastener is mounted similarly to yours.

[Whiskey]

I took a spirited drive today on 56, from Athens to Lake Hope State Park and back. I am itching for spring and the buds will be out by mid-April.
Here are some pics by Lake Hope, near Zaleski, Ohio. And yes, I wear a license up front in Ohio. Also, a link to the google map of the twisting banking road. You feel like you can carve into the the pavement on many of the turns. http://maps.google.com/maps?f=d&hl=e...31213&t=h&z=12

[Whiskey]

Ok, ok... enough with the 800px wide pictures. But, here are some more in case you didn't get a real good look.

[Whiskey]

Engine cover, interior console, ac, and side ducts.

[fishtaco]

Nice work. I like it a lot but I'm not as brave as you.

[CloneTroop]

Wow, nicely done.

[Whiskey]

In case you are wondering about the bends in the brackets.
See post #28 for actual pictures.

[Pato]

Nice work

[Shawn C]

Everyone wants to be an Exige lol Looks great!

[megatron]

Not my cup of tea, but nicely done and very good documentation of your process. By the way you have got to be the only Elise/Exige in Ohio with a front plate.