My "summer" project comes to a close...for now - LotusTalk - The Lotus Cars Community
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post #1 of 11 (permalink) Old 02-11-2019, 05:45 PM Thread Starter
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My "summer" project comes to a close...for now

My project is finally coming to a close so I thought I'd share where I ended up.

I have a few more things planned for later this year, wheels, brakes, and suspension mostly. But I am pretty happy with where she is now!

Huge thanks to LotusTalk and the folks that helped with the advice I needed here and there. There are so many good resources right here on this forum, as you all know. It can tough to find sometimes but it's all there!
Big shout out to Greg at GRP who has supplied with me with a ton of my kit.
Also BOE, MWR, BWR, Inokinetic, Lotus Garage/BRG, McMaster-Carr, Torqued.io, HMS Motorsport, M&M Motorsports were all frequented by me many times this past year. Just tons of great service and support all around!
And a big thanks to my wife who helped a TON, especially with the roof and the seat installs!

Pictures - Use the "Feed view" if you want to see things in sequence with my comments along the way (sorry I only have a Facebook album for now)

2007 Lotus Exige S Project
Purchased: March 2018
Delivered: April 2018
Project Start: May 5, 2018 End: February 10, 2019
Total hours - 223
Total spent - (sshhh...my wife might find this page one day)

Task (hrs) - (not quite in order)
Remove clam(s) - 5
Replace radiator - 2
Refill coolant - 1
Upgrade front and rear turn signals/markers/backup lights to LED, swap relay - 2
Replace coolant hoses - 15
Clean underpinnings - 3
Install Moroso coolant tank - 1
Replace brake lines, fluid, inspect rotors - 12
Tape over inlet ducts - 0.5
Bleed brakes/clutch - 1
Replace door striker with BWR kit 1
Remove old and Install new headliner - 15
Install ECU - 0.5
Install 3.0" pulley - 5
Replace belt
Fuel injectors - 4
Install CAI kit - 2
Change Transmission fluid - 2
Oil and filter (need to add oil) - 2
Install Radium catch cans - 2
Replace radiator shroud
Install new shift knob 0.5
Install banner - 0.5
Install GRP side skirts - 10
Install Tillett racing seats driver/passenger with fixed mounts - 20
Complete toe alignment
Replace diffuser with Difflow Railer Jr - 2
Replace exhaust with BOE QS - 3
Replace steering wheel - 3
Complete gauge and audio harness - 10
Install gauges - 5
Extend gauge wiring
Install single-DIN gauge holder
AFR gauge and sensor
Boost gauge and sensor
Clock gauge
Customize console - 15
Install button console
Wrap shifter cage, button box, and cupholder
Install edge trim onto center console
Install RHD center tunnel
Replace cat pipe with decat pipe - 5
Coat manifold and decat pipe, reinstall
Install air pipe plugs
Cut off air pipe
Install MWR shifter stiffener - 1
Replace Toe links - 5
Spark plugs (need a gapping tool) - 1
Washer fluid (removed bottle)
Torque down pulley nut (60 ft-lbs)
DRL mod - 0.5
Install Escort harness and detector - 5
Install new front/rear engine mounts - 5
Remove airbag computer - 2
Replace stereo - 10
Remove excess wiring
Remove head unit
Remove subwoofer
Remove speakers
Replace speaker wires
Install bluetooth amplifier
Replace speakers with JL upsize
Install clam(s) - 3
Replace OEM turn signal trim
Repair OEM turn signal clip with tie-down
Replace wheel well RAWL nuts and hardware - 1
Replace rear panel with Eliminator V3 - 1
Replace diffuser mounting hardware with BWR kit
Replace tail lights with GRP custom lights - 1
Replace battery, install CTEK harness - 2
Replace fuses - 0.5
Replace floormats with full width Inotek
Replace floor mat buttons
Install tow hook - 0.5
Install wing plugs
Install Schroth Flexi 6pt harness and harness kit (8)
Install Difflow Aeroplates - 4
Wash, detail, final project cleanup - 2
Nukey - 0.5
Install BOE Oil pan - 10
Ship ECU to BOE
Inspect cams, replace valve cover gasket(s) - 2
Remove heat shield - 1
Patch harness insulation - 1
Remove driver and passenger airbag - 5
Re-torque EVERYTHING after several heat cycles - 1
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-Smoky
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post #2 of 11 (permalink) Old 02-13-2019, 05:12 AM
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I started looking at the pictures... an hour later I realized I was still looking. Amazing work.

Now i'm just hoping you kept a spreadsheet of all the parts!
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2007 Exige S Phantom Black
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post #3 of 11 (permalink) Old 02-13-2019, 09:03 AM
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Are you planning to fit a wing onto to her? To me an Exige looks awkward without a wing. Otherwise, great build!
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post #4 of 11 (permalink) Old 02-13-2019, 09:17 AM Thread Starter
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Quote:
Originally Posted by rb26dett View Post
Are you planning to fit a wing onto to her? To me an Exige looks awkward without a wing. Otherwise, great build!
For now, no. Can't yet find one I really like, but I do like the clean pure aero look of an Exige with no wing so I thought I'd try it for a while. Pretty happy with it right now!

-Smoky
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post #5 of 11 (permalink) Old 02-13-2019, 10:44 AM
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You should bring it over to Lake Charles so I can hear that QS.
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post #6 of 11 (permalink) Old 02-13-2019, 10:58 AM
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looks great! You're a brave driving around on the street with 6pt harness. Are those tillet seat rails, or custom?

"Give a man a match, and he'll be warm for a minute, but set him on fire, and he'll be warm for the rest of his life."
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post #7 of 11 (permalink) Old 02-13-2019, 11:20 AM Thread Starter
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Quote:
Originally Posted by jds62f View Post
looks great! You're a brave driving around on the street with 6pt harness. Are those tillet seat rails, or custom?
Thanks!

I've had many cars where I used a harness full time street and track. I always feel "loose" in an OEM 3-point, like I'm not really in the car. Just feels wrong. Personal preference.

Yes Tillett brackets both sides. Inokinetic sub-strap and floor plates, with Class 10 metric hardware all around from McMaster-Carr. Install was a beast but well worth it!

-Smoky
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post #8 of 11 (permalink) Old 02-13-2019, 01:15 PM
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Nice work! I like all the blue accents, really sets the car off. Wingless is a different look for sure, but it looks sleek like that. Sounds like you are planning on tracking it? If so, did you go with a baffled fuel tank or the BOE surge tank? I didn't see either in your mod list.
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post #9 of 11 (permalink) Old 02-14-2019, 10:07 AM Thread Starter
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Quote:
Originally Posted by Scott M View Post
Nice work! I like all the blue accents, really sets the car off. Wingless is a different look for sure, but it looks sleek like that. Sounds like you are planning on tracking it? If so, did you go with a baffled fuel tank or the BOE surge tank? I didn't see either in your mod list.
Our tracks are pretty small and tight down here. Prob make a run a few times a year. I don't have time for much else. If it becomes an issue I'll consider it but will definitely keep an eye out. I am looking for an excuse to replace with a larger fuel pump which would then naturally lead to a larger/baffled tank.

-Smoky
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post #10 of 11 (permalink) Old 02-15-2019, 10:10 AM
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Regarding times...

Reading your post one - 1 hour


Great looking car!
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post #11 of 11 (permalink) Old 02-15-2019, 11:19 AM
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Amazing work and attention to details!
Thanks for sharing.
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