Bringing an Exige S back from the dead -- (re)build thread - Page 5 - LotusTalk - The Lotus Cars Community
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post #81 of 117 (permalink) Old 08-20-2018, 06:31 PM Thread Starter
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What are people's opinions on gold foil heatshield a la McLaren F1 on the firewall? If ever there's a time to do it, it's now but does it make a difference really and does it dampen sound at all?

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post #82 of 117 (permalink) Old 08-20-2018, 09:02 PM
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Originally Posted by chiarov View Post
What are people's opinions on gold foil heatshield a la McLaren F1 on the firewall? If ever there's a time to do it, it's now but does it make a difference really and does it dampen sound at all?

Nice work on what you have done, it looks really good.

In terms of grill...no idea, but i would probably just paint it personally and then just touch it up as needed. Even powder coating won't survive a rock dead on.

In terms of the gold foil, as I went through the same thoughts. Heat reduction to the cab, it will do. Looks great, it will do. Noise reduction, fails on that one. To thin. I don't k ow bow much heat it will reduce, but when I considered it, I just didn't think I could make it look that good over the carpet sound deadening material so I passed on it. As it does great to reflect heat directly, but not sure it would do as well for absorbed heat if it was directly on the firewall.

Personally, put a good quality sound deadening inside and call it good.

Nice job, and keep it up!!!

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post #83 of 117 (permalink) Old 08-21-2018, 06:19 AM
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Compared to the stock firewall insulation, the effort required to install gold foil doesn't seem worthwhile for the slight improvement in cabin temps. The problem is the rear glass seal leaks like a sieve when it comes to heat and noise. Add to that the heater matrix lines just below the dash and the lines in the sills for the oil cooler(s) and coolant and you still have a hot cockpit.

However, it sure does look pretty when done right!
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post #84 of 117 (permalink) Old 08-21-2018, 09:10 AM Thread Starter
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Thanks for the comments @Giantmcm and @+TSRAGR !

I think you've both convinced me not to bother with the gold foil heat shielding. I'd have to pull off all the carpeting stuff plus the various components mounted on the firewall for dubious benefit so it just doesn't seem worth the hassle. Plus, this will be a street car with trackday usage, not a full out racecar or anything.

We did put in some sound deadening material when we had the interior rear panel off, so hopefully that helps a little on the noise.

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post #85 of 117 (permalink) Old 08-21-2018, 11:41 AM
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Not sure on price, but there is this stuff: https://www.aerogel.com/pyrogel/
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post #86 of 117 (permalink) Old 08-21-2018, 03:45 PM Thread Starter
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Also thinking about doing something with the 3rd and 4th gears while the transmission is out and the Quaife is being installed -- as I know they're a weak point in the system.

Anyone have experience with cryo treating them? I know there are other gear options but they're all pretty expensive.

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post #87 of 117 (permalink) Old 08-22-2018, 11:49 AM
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Quote:
Originally Posted by +TSRAGR View Post
Compared to the stock firewall insulation, the effort required to install gold foil doesn't seem worthwhile for the slight improvement in cabin temps. The problem is the rear glass seal leaks like a sieve when it comes to heat and noise. Add to that the heater matrix lines just below the dash and the lines in the sills for the oil cooler(s) and coolant and you still have a hot cockpit.

However, it sure does look pretty when done right!
Anywhere that exhaust gases/smells could creep into the cabin? The shifter tunnel? Rear glass seals?

Can't tell from the pic if there's an opening to the side sills.

** save ~10 lbs gain 1 hp ** EQ: Y=(190*X) / (1984-X) where Y is (HP) and X is (lbs)

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post #88 of 117 (permalink) Old 08-24-2018, 06:07 PM
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Great build!
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post #89 of 117 (permalink) Old 09-03-2018, 04:34 AM
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This is so inspiring! I neither have a garage, tools or expertise to do a project of this caliber. It certainly gives me more confidence in rebuilt Exiges from reputable dealers like wirewheel. Thanks!
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post #90 of 117 (permalink) Old 09-04-2018, 09:10 PM Thread Starter
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This is definitely the biggest project I've every undertaken so appreciate the encouragement and support.

I totally agree with you that people shouldn't be afraid of rebuilt Lotuses, especially from folks like Wirewheel who are absolute experts on these cars. Once you have one all apart and you see how simply they're actually built, you realize that they can definitely be rebuilt to a very high standard. As long as the suspension attachment points and aluminum chassis aren't damaged, literally everything else is just bolted or glued to that!
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post #91 of 117 (permalink) Old 12-08-2018, 05:18 PM Thread Starter
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I haven't updated this thread in ages, but that's because the project had pretty much stalled. With my buddy busy remodeling his house and in need of his expertise for some of the next steps with the engine swap, I've basically been sitting on my thumbs.

I took the spare transmission (which came with the new engine) to Trakspec to install the LSD, and while they had everything apart Jon mentioned (as others on LotusTalk know) that the 3rd and 4th gears tend to be problematic in higher HP cars and that I should upgrade them while everything was apart. Not wanting to shell out the big bucks for the replacement gears, I opted to have the whole thing cryo-treated so I sent off all the gear internals and shafts to get that work done. I dunno if it'll help or not, but a few engine builders I know swear by cryo treatment so I figured it was worth a shot for $300.



Anyway, hopefully things will get moving along here because my buddy (where the car is stored) informed me that he's moving soon so we need to get it operational rather than tow it somewhere else. Stay tuned for more updates (I hope!)

The only problem this presents is that we might have to install the new engine with the existing transmission since I don't think the new transmission with the cryo'd gears will be ready in time (I'm still waiting to get the gears back). A bit extra work, but at least we can drive it around for awhile for a before/after comparison of the LSD.

2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue

Last edited by chiarov; 12-15-2018 at 06:12 PM.
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post #92 of 117 (permalink) Old 12-08-2018, 05:20 PM Thread Starter
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Oh and thanks for the recommendations on the front grill. They're backordered for ages from Lotus, so I bent it all back into shape and have it being powder coated. For reference if anyone else is looking to have one re-done I believe "satin black" is the closest match to the OEM color on the grill.


2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue

Last edited by chiarov; 12-15-2018 at 06:10 PM.
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post #93 of 117 (permalink) Old 12-12-2018, 05:55 PM Thread Starter
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Got the replacement engine on an engine stand the other night and started prepping it for install. Should have more updates on that Friday when I have some more time to work on it.

Basically need to:
- Change fuel rail / injectors
- Remove OEM intake manifold / throttle body
- Install BOE300 supercharger
- Remove OEM exhaust header
- Swap to baffled oil pan
- Install laminova sandwich plate

And probably a hundred more little things I'm not thinking about right now.

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post #94 of 117 (permalink) Old 12-15-2018, 07:02 AM Thread Starter
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Little bit more progress this evening! (Let me know if these pics don't load?) Huge thanks to @forkmeupscotty for an extra set of hands!

1 - removed OEM oil pan and installed baffled oil pan (Guide on How-Tune.com is really good!)







2 - Removed OEM sandwich plate and installed the one that came with the Laminova kit from elise-spares.com



3 - Modified coolant U-tube (cut out the long line with the metal U bend and just made a shorter connecter per BOE 300 install instructions).

4 - Removed oil sling tube and ordered block off plates from GRP

5 - Removed OEM intake and test fit BOE300 supercharger + relocated alternator

Stay tuned for more...

2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue

Last edited by chiarov; 12-15-2018 at 06:10 PM. Reason: fixed images
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post #95 of 117 (permalink) Old 12-20-2018, 07:58 PM Thread Starter
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Gears back from the cryo shop and transmission reassembled (with the new Quaife LSD) by the good folks at TrackSpec! Thanks @Jonvo .

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post #96 of 117 (permalink) Old 12-20-2018, 08:04 PM Thread Starter
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Supercharger and manifold installed, U-tube modified, alternator relocated (part of the BOE300 kit), bigger injectors installed, bunch of other little stuff to get the replacement engine ready to go into the car. Ordered oil sling tube block off plates from GRP so will install those Saturday and remove the wiring harness since there is already one in the car (that has been modified as needed for the BOE300 kit by the previous owner.)

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post #97 of 117 (permalink) Old 12-22-2018, 09:00 PM Thread Starter
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Added GRP oil sling tube block off plates per a lot of references (such as the BOE300 install instructions) that say this tube is useless.




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2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue
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post #98 of 117 (permalink) Old 12-22-2018, 09:01 PM Thread Starter
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Reinstalled serpentine belt, much easier with the engine already out of the car!


2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue
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post #99 of 117 (permalink) Old 12-22-2018, 09:05 PM Thread Starter
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But spent most of the time today watching glue (ok, actually polyurethane) dry. *YAWN* Ended up using the Sika construction adhesive mentioned in another thread on here. It seems similar to the OEM stuff, but is gray instead of black.

I had to devise various ways of holding the front grills in place while the adhesive set, so I got creative. Probably not the way it's done at the factory but should hold things in place I hope! These grills aren't under a lot of stress, but they do see a good bit of wind pressure and vibration.

If I recall, the antenna wire was also glued under the front clam so I need to glue that back in as well.






2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue
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post #100 of 117 (permalink) Old 12-23-2018, 09:23 AM Thread Starter
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I might just tape the antenna back in place. Any recommended special tape for fiberglass?

2012 Porsche 991.1S white
2007 Exige S arctic silver (project)
2005 Elise magnetic blue/biscuit
2014 Audi Q5 3.0T scuba blue
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