Base car to Cup car, the evolution of my Exige. - LotusTalk - The Lotus Cars Community
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post #1 of 181 (permalink) Old 04-12-2018, 11:10 AM Thread Starter
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Base car to Cup car, the evolution of my Exige.

OK, so last year about April I decided to convert my car to a Cup 190 clone.

The conversion would be a loose one because I planned to use parts from the 190/240/255 & 260 Cup cars to make my personal dream Cup car. The factory Cup race cars have always been my favorites, but not being legal on the street, I figured I'd just convert mine. It would end up being legal (relatively), and give me the look I was after. I also never plan to actually race the car, I just like the additional detail of the race cars. They really are just bolt-on cars anyway, save for the T45 roll hoop/stays, and roll cage. Even Lotus did not make the 190/240/255 cars on the line, they were 90% assembled and then went to a separate building for fitting of the motorsport parts.

So, first up was to make a list of all the differences between my base Exige, and the Cup racing cars, then just delete/change anything I didn't like about them. Some of these parts I already had, which was nice, others were going to cost me an arm and a leg, but so be it.

This is the list:

- 240R Cup wheels
- Yokohama A005 slicks
- 308mm 2-piece front rotors (doing these front and rear)
- AP Racing 4-pot 7624 calipers w/adapters (doing these front and rear)
- Lotus Sport Ohlins suspension (I chose the street version, valved and sprung for the A048 instead of the race version)
- Triple Pass all-aluminum radiator
- Front fog lights (never liked these, leaving them out)
- Front headlight black-out kit (having carbon fiber covers made for easy removal)
- Fender Lotus Sport decals (I added these, but didn't like the edgy look, so I put Cup decals all around)
- Rear Cup decals
- Rear Union Jack badge (after installing this it just seemed out of place. Swapped it with a black/chrome version and it's much better)
- Lotus Sport racing driver's seat (not doing this seat, having custom carbon fiber Lotus Sport seats made)
- Sparco Cup 300mm steering wheel with quick release (didn't do the quick release, it puts the wheel too close to me)
- Back-up steering wheel is the original Nardi Cup wheel. I had mine made by the Lotus trim shop with black alcantara, which was a rare option.
- Dash plate for the fire suppression and kill switches (custom fit to the newer dash)
- Fire suppression system
- Master switch system
- Build plate
- Accusump system (probably not doing this, they tend to have problems)
- Lightweight battery
- Roll cage (not doing this mod)
- T45 roll hoop and stays (not doing this mod)
- Cattless exhaust with tune
- Front and rear side markers delete (not doing this mod either, unless the car has to be repainted as a whole)
- Radio/speaker delete
- Cup car airbox

Some S260 road car bits that I had in mind.

- S260 Carbon fiber hatch
- S260 Carbon fiber rear spoiler
- S260 Carbon fiber roof

And some bits I already had.

- Carbon fiber front splitter
- Carbon fiber side intakes
- Carbon fiber door panels/pulls
- Carbon fiber dash

When all is said and done, I may drop the car off at BOE to get a REV300, but owning the car since 2009, I've since been very happy with the power, and the tune that Phil put on the car.

I'll start with the interior transformation.

The interior with just a few carbon bits:

Carbon & Aluminum. *Explored*
by Andrew Thompson, on Flickr

Tecnocraft Composites carbon fiber dash, no speaker holes:

Closer.
by Andrew Thompson, on Flickr

P300 Sparco Cup wheel with standard hub from Sector111, and some alcantara bits:

260 Cup Dreams.
by Andrew Thompson, on Flickr

Custom temporary radio-delete plate, and console delete.

Console delete
by Andrew Thompson, on Flickr

OEM Cup 240/255 dash plate with switches. This is a custom job because this plate was made for the earlier dash.

Retro Love.
by Andrew Thompson, on Flickr

Lotus Sport floormats from Italy.

Coming together. (Explore)
by Andrew Thompson, on Flickr
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2006 Exige

Last edited by VisualEchos; 05-07-2018 at 10:20 AM.
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post #2 of 181 (permalink) Old 04-12-2018, 11:18 AM Thread Starter
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And some parts pictures:

Cup 240R wheels in high-power silver and Yokohama A005 slicks.

A005 Dreams
by Andrew Thompson, on Flickr

Lotus Sport Ohlins, one of the very last sets made.

Christmas comes early.
by Andrew Thompson, on Flickr

OEM S260 carbon fiber rear spoiler.

S260 Cup carbon fiber spoiler
by Andrew Thompson, on Flickr

OEM Cup windshield banner.

OEM Windscreen Decal
by Andrew Thompson, on Flickr

Canisters mounted on the rear stays.

Ohlins
by Andrew Thompson, on Flickr

OEM Lifeline Zero 2000 fire suppression system.

Zero 2000
by Andrew Thompson, on Flickr

OEM stickers, and one of a kind build plate.

Decals, decals, decals...and a one-of-a-kind Lotus Sport build pate.
by Andrew Thompson, on Flickr

2006 Exige
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post #3 of 181 (permalink) Old 04-12-2018, 11:20 AM Thread Starter
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Mock up of the front brakes, with possible logo color change. I'll probably leave them yellow though.


Closer
by Andrew Thompson, on Flickr

Fire suppression and master switch rings installed. More on that later.

Fire Suppression and Master Switch rings fitted.
by Andrew Thompson, on Flickr

2006 Exige
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post #4 of 181 (permalink) Old 04-12-2018, 11:25 AM
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I would say if you are doing all of this, you are more than capable of installing a REV400 yourself. I say REV400 as it will cost less to install than having BOE install a REV300 for you.

Good luck, looks like a fun project.
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post #5 of 181 (permalink) Old 04-12-2018, 11:29 AM Thread Starter
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Some more random pix.

OEM S260 Cup roof


Mocking up the brackets inside the rear of the roof.


Roof clunk bolt backs.


Front brakes.


More brake pix. 7624 FTW!


Rear brake mock-up. I've changed this though, they will be mounted inside instead of outside.


Rear Cup decal and OEM UJ badge sorted.

UJ badge & Cup decal.
by Andrew Thompson, on Flickr

2006 Exige

Last edited by VisualEchos; 04-17-2018 at 10:57 AM.
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post #6 of 181 (permalink) Old 04-12-2018, 11:32 AM Thread Starter
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Quote:
Originally Posted by XtinctElise View Post
I would say if you are doing all of this, you are more than capable of installing a REV400 yourself. I say REV400 as it will cost less to install than having BOE install a REV300 for you.

Good luck, looks like a fun project.
Either is a real waste of money for my purposes, really, but as Phil says "Most of what you're doing is a waste of money as measured by many.... so why try to keep track now?"

I may waste that money one day though, on one or the other.

2006 Exige
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post #7 of 181 (permalink) Old 04-12-2018, 11:42 AM Thread Starter
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The process of installing the external fittings.























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2006 Exige
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post #8 of 181 (permalink) Old 04-12-2018, 11:46 AM
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beautiful car... and I know addiction of modifying a car all too well myself to make it exactly what you want it to be... I'm having to fight it on my own Exige until after I finish a few other cars.
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post #9 of 181 (permalink) Old 04-12-2018, 11:47 AM Thread Starter
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beautiful car... and I know addiction of modifying a car all too well myself to make it exactly what you want it to be... I'm having to fight it on my own Exige until after I finish a few other cars.
Thanks man. I kept the mods really light on the Exige for several years, just the basics, but I've had the car for 9 years, so it's time to do what I've always wanted to do.

2006 Exige
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post #10 of 181 (permalink) Old 04-12-2018, 12:10 PM Thread Starter
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And some more random pix.

Mmmm, fresh 240R Cup wheels in high-power silver.


Carbon dash, less than 1 lb


Carbon door panels


Carbon door pulls


Carbon gas door from GRP. GRP FTW!


Carbon rear speaker blanks


Carbon side intakes


Custom carbon rear license plate section. GB Composites.


Carbon front lip from Sector 111


Deka battery with RLS bracket


New OEM diffuser


Catless Larini dual-tip SE


Another shot of the external rings


Radium coolant tank


Radium Ti lugs


Steering arms

2006 Exige
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post #11 of 181 (permalink) Old 04-12-2018, 12:26 PM
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Awesome build so far! Was it hard to install the master switch and fire suppression system?
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post #12 of 181 (permalink) Old 04-12-2018, 12:43 PM Thread Starter
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Awesome build so far! Was it hard to install the master switch and fire suppression system?
Thanks. Still working on installing the systems, many irons in the fire. Doesn't look hard, just simple bits really, more time consuming than anything.

2006 Exige
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post #13 of 181 (permalink) Old 04-12-2018, 01:38 PM
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How's the NA tune from BOE?
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post #14 of 181 (permalink) Old 04-12-2018, 01:41 PM Thread Starter
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Quote:
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How's the NA tune from BOE?
Dude, it was magical. Revs smoother, 2nd cam transition is nearly gone, more power at every rpm. No way I can overstate how much nicer the car drove immediately.

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post #15 of 181 (permalink) Old 04-12-2018, 02:25 PM
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Dude, it was magical. Revs smoother, 2nd cam transition is nearly gone, more power at every rpm. No way I can overstate how much nicer the car drove immediately.
I've been putting the tune purchase off for years now. I actually was going to order last year and never got a reply to the e-mail I sent to BOE. I have my tune info sheet all filled out and ready to go. But anyway, that is a great review. Ever have any stalling probs? I've heard the NA tune will sometimes have stalling or hard starting. My '06 Exige runs so well as it is now, but I'd love a bump in power and the lower cam switch.

Your car is looking great!

What about going back to the aluminum gas cover for continuity?
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post #16 of 181 (permalink) Old 04-12-2018, 02:33 PM
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Also, how much did that carbon license plate section cost you? I like that.
Any problems with the heat there?
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post #17 of 181 (permalink) Old 04-12-2018, 02:38 PM Thread Starter
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I've been putting the tune purchase off for years now. I actually was going to order last year and never got a reply to the e-mail I sent to BOE. I have my tune info sheet all filled out and ready to go. But anyway, that is a great review. Ever have any stalling probs? I've heard the NA tune will sometimes have stalling or hard starting. My '06 Exige runs so well as it is now, but I'd love a bump in power and the lower cam switch.

Your car is looking great!

What about going back to the aluminum gas cover for continuity?
Never had any issues with the tune at all. The only issue I ever had, and still have, is the car is really "cold" for the first couple of miles...even if it's 100° outside. No one has ever been able to tell me why that is either, the Celica's don't do that...

But truth be told, that's my favorite time! Why? MUCH more pops and cackles. If I had it my way, it'd be COLD all the time, sounds tremendous.

I hate the stock fuel door. As crazy as this sounds, I'll probably end up with a dry brake system like on the GT3 race cars. It's a look I like.

Quote:
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Also, how much did that carbon license plate section cost you? I like that.
Any problems with the heat there?
I can't remember, a few hundred bucks (rape), but it's nice. It's just a thin piece of carbon, drilled the holes, mounted it with 2 sided tape. No problem with heat at all.

2006 Exige
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post #18 of 181 (permalink) Old 04-12-2018, 04:08 PM
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Excellent work and pictures as always
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post #19 of 181 (permalink) Old 04-12-2018, 04:22 PM Thread Starter
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Excellent work and pictures as always
Thanks bro!

2006 Exige
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post #20 of 181 (permalink) Old 04-12-2018, 04:52 PM
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looks nice, how are you attaching the 4 pots to the rear? custom braket? front uprights moved to the rear?
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