Complete Exige rebuild - LotusTalk - The Lotus Cars Community
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post #1 of 76 (permalink) Old 03-17-2019, 03:10 PM Thread Starter
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Complete Exige rebuild

Car is finally here in New York. Took for a fun test drive today little scary with current condition of the car, but hit 80mph few times through the industrial complex. Now that I now everything is work ok, Engine performances was amazing, Transmission shifted well (even with bent shifter) actually think the bend took out some of the slop.

Disassembly will start this week. I’ll try to post as many photos as I can for those that are interested. Also I’m sure I’ll refer to this site for how to help and up grade ideas while car is apart. Differently thinking of hinged rear clam and all aluminum radiator at top of list.
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post #2 of 76 (permalink) Old 03-17-2019, 03:16 PM
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The frame looks completely bent unless I'm not seeing something. I'm surprised you drove it to 80mph in its current form as I can see how dangerous it can be. Good luck with the rebuild though
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post #3 of 76 (permalink) Old 03-17-2019, 03:23 PM
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So you drove it without a door? I see youíre in NY. Iím in NJ and itís still pretty damn cold here. Good luck with the build.
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post #4 of 76 (permalink) Old 03-17-2019, 03:24 PM Thread Starter
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Surprisingly wheels seem inline. I did a few slow passes and tried little faster and hard on gas to test if it would act strangely. But could feel good responses, no dog tracking or loose rear car steady straight even with hard shifts. I did belt in just to be safe.

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post #5 of 76 (permalink) Old 03-17-2019, 03:25 PM Thread Starter
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So you drove it without a door? I see you’re in NY. I’m in NJ and it’s still pretty damn cold here. Good luck with the build.
Haha yes door and top off. I work outside everyday 2 miles off Lake Ontario. If it’s 30 or above I’m hot. Hardest part was seeing through windshield.

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post #6 of 76 (permalink) Old 03-17-2019, 03:28 PM
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Haha yes door and top off. I work outside everyday 2 miles off Lake Ontario. If itís 30 or above Iím hot. Hardest part was seeing through windshield.
I was born in the jungle of Southeast Asia so anything below 70 is cold to me. Lol
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post #7 of 76 (permalink) Old 03-17-2019, 03:29 PM
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Iím impressed you drove that at all let alone up to 80.
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post #8 of 76 (permalink) Old 03-23-2019, 08:09 AM Thread Starter
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Finally a day I can work on the car. Seats out, right door off. Had to cut rocker off to remover left seat. Working on rear clam next.
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post #9 of 76 (permalink) Old 03-23-2019, 08:44 AM
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That chassis is the definition of scrap!
No one is qualified or has the jigs to repair that chassis except Lotus.

Whoever said that island life is great was never committed to Alcatraz...
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post #10 of 76 (permalink) Old 03-23-2019, 12:55 PM Thread Starter
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That chassis is the definition of scrap!
No one is qualified or has the jigs to repair that chassis except Lotus.
Chassis from a different car on the way!!

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post #11 of 76 (permalink) Old 03-23-2019, 12:57 PM Thread Starter
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Good days work. 😃
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post #12 of 76 (permalink) Old 03-23-2019, 01:00 PM Thread Starter
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If you read my other posts I heard a clunking sound. Thought it was the frame separating during shifts. Well found source of the sound. Mount pulled off the transmission. Luckily I’ve welded worse. Easy fix once I get engine out.
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post #13 of 76 (permalink) Old 03-23-2019, 01:15 PM
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You're making good progress. I've been installing oil pressure and temp guages and it's taken me all winter. Doesn't help I get to work on it an hour at a time.
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post #14 of 76 (permalink) Old 03-23-2019, 01:22 PM Thread Starter
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You're making good progress. I've been installing oil pressure and temp guages and it's taken me all winter. Doesn't help I get to work on it an hour at a time.
Had about 8 hours free today. Except for the 4 customers that came to pick up engines and body guy was there talking way to long about doing the repairs. Will give him the rear clam first. He is a professional boat repair shop, knows his fiberglass.

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post #15 of 76 (permalink) Old 03-24-2019, 09:33 AM Thread Starter
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Front clam is almost ready to come off but will do some sanding first I think. Anyone have ideas on removing star shield ?

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post #16 of 76 (permalink) Old 03-24-2019, 12:28 PM
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Patience and a heat gun
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post #17 of 76 (permalink) Old 03-24-2019, 04:07 PM Thread Starter
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Patience and a heat gun
My body guy said the same thing

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post #18 of 76 (permalink) Old 03-25-2019, 04:48 PM Thread Starter
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Body guy found 3 layers of paint on rear clam. Either Lotus painted it twice plus one repair or previous owners were very unlucky.

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post #19 of 76 (permalink) Old 03-26-2019, 09:49 AM
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Jesus, this is quite the project. Subbed for progress!

Thinking of K-swapping? Here's an idea of the cost involved.

2006 LOTUS EXIGE (ASPEN WHITE) Honda K24A2 + MPx90 supercharger. 322whp/271lb-ft @13psi. Build thread here.
1994 AUTOZAM AZ-1 MAZDASPEED Japanese Super Kei!
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post #20 of 76 (permalink) Old 03-26-2019, 02:10 PM Thread Starter
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Jesus, this is quite the project. Subbed for progress!
Hopefully by the end of this weekend motor will be out.

Wheels going out for powder coating tomorrow. Sorry guys I can’t stand black wheels on any car.

New set of R888R’s coming in along with many other nice new parts.
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Last edited by Partsfinder; 03-27-2019 at 03:21 PM.
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