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400/GT Red Oil Pan - Rubber to Metal Trap Doors

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179 views 10 replies 7 participants last post by  shimstack  
#1 ·
A while back I picked up a red oil pan from a local Lotus club member who had installed the Moroso pan.

I wanted to see if I could replace the rubber trap doors in the oil baffles with metal for a permanent, maintenance free solution to better oil control for far less $$$ than the Moroso pan. Today I dug into it.

The patient:



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I used a cutoff wheel on the Dremel to cut through the 6 small welds that hold the baffle assembly to the outer pan:

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I made five new trap doors from a piece of stainless piano hinge leftover from another project:

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Tack welding the pin to the outer ends of the barrel so these can't come apart in use:

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Doors welded in place with lots of double checking to ensure they swing freely and don't stick or bind:

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Thin metal in tight spaces is tricky to get a pretty bead. If I had it to do again it would be better as I developed my process along the way. Also, I cooked the inner baffle assembly in a (not used for food) toaster oven to burn the oil out of the surfaces of the metal for cleaner welds:

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Outer pan cleaned and ready to receive the baffle assembly:

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The outer pan didn't fit in the toaster oven and the welding was more difficult. Thankfully there isn't really anything trying to separate the two pieces. The paint on the outside of the pan burned within a second of starting the arc. I resorted to shorter welds and a few more of them vs. the factory approach:

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Crispy:

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And finished off with a love note to a future caretaker:

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I've prepped this piece to go on during my header install, along with the oil cooler line update, and another trans flush.

Can we read oil pressure over CAN? A big motivation to do this was to ensure better oiling for track days on 200TW tires in the future. I don't think I'll get good before/after data, but I would be nice to confirm safe PSI once it's installed.
 
#2 ·
Can we read oil pressure over CAN? A big motivation to do this was to ensure better oiling for track days on 200TW tires in the future. I don't think I'll get good before/after data, but I would be nice to confirm safe PSI once it's installed.
Stock these cars only have an oil pressure switch. You'll need to add your own pressure sensor to get that data.
 
#5 ·
Considering this is so common in aftermarket oil pans I'm not expecting any sticking or degradation. I tweaked each one with a pliers after the welds cooled to make sure they sit flat and swing freely. If anything they'll be more lubricated sitting in a bath of oil? I'll stick an endoscope camera through the drain hole when I change the oil the first few times.
 
#6 ·
Do these metal doors offer the same resistance to movement as the rubber ones? I have a set of brand new rubber flaps ready to go on, so I know that they aren't very stiff. But there is still some resistance to movement. If you put the pan on its side, will the metal flaps open to the same degree as the rubber ones, for example?

What I'd love to see is someone to use what the OP has done, but with a more scientific approach. Essentially, someone who tracks their Evora with the stock red pan and performs a series of oil analyses. 1-2 with the stock rubber setup and 1-2 after someone does this with the above setup. Or potentially some oil pressure analyses while on-track (both before and after the mod) like I've seen some BRZ/86 owners do to show differences in oil pressure when the car goes around turns.
 
#7 · (Edited)
Do these metal doors offer the same resistance to movement as the rubber ones? I have a set of brand new rubber flaps ready to go on, so I know that they aren't very stiff. But there is still some resistance to movement. If you put the pan on its side, will the metal flaps open to the same degree as the rubber ones, for example?

What I'd love to see is someone to use what the OP has done, but with a more scientific approach. Essentially, someone who tracks their Evora with the stock red pan and performs a series of oil analyses. 1-2 with the stock rubber setup and 1-2 after someone does this with the above setup. Or potentially some oil pressure analyses while on-track (both before and after the mod) like I've seen some BRZ/86 owners do to show differences in oil pressure when the car goes around turns.
The metal doors hang freely vertical to whatever angle you tilt the pan. The rubber flaps do have some resistance, but it doesn't feel like it could restrict the oil movement in any meaningful way. Since the objective here is to keep the oil near the pickup, any tendency toward migration from lateral g forces will act to close the doors and choke the flow.

It's also worth mentioning that this is going in my 2011 Evora S as an improvement to no baffling- I can't speculate that there's a performance benefit/deficit between rubber or metal doors in this pan.

Looks like Wilhelm has done a bunch more work since I last visited. Here's a bunch of oil pressure science on a 2GR that sees high g-loads regularly:

 
#10 ·
Nice work! I think my only concern with a solution like this would be is there enough clearance in the hinge to allow for thermal expansion. Wouldn't want the hinges to bind when they get hot.

Jubu makes this option:
Would be nice if there were an option to order a pan with these already installed.