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DJ Wilmas Elise 111S S2 K series 1.6 Turbo

67K views 235 replies 34 participants last post by  The Ref 
#1 ·
As you all know i sold the engine in the Metro to another metro owner, build thread is on Metropower, so he can be the first to be over 300bhp and with the cash i told my pregnant wife we needed a new family car so i bought this 2005 Cat C Elise 111S the last of the k series powered cars (160bhp on lotus management)

As for the 1.4, people seem to be disappointed that i only got 292.8bhp with the engine, not i, the only reason i sold the car was to buy an elise as the metro was fun.....but it wasnt designed to go over 100mph and go round corners. Also for the record when we split the car the intercooler was split, so it should of been quicker and thats why i was having low down power issues.



I am hoping to build it on a budget less than the price of a straight low mileage 111S after using the knowledge from the metro

Needs a little work and its with the infamous Cheeky Scott we will get it put back together and re-sprayed black.

There is no chassis damage just front and rear clams and a few minors repairs

Plan is to get the car back on the road with the std engine, whilst building the turbo block

I thought long and hard about what engine to use, i was tempted by the VAG and T series but ultimately for me they are too heavy with the S2 already being over 800kgs. Honda just doesnt appeal to me (sorry Munday) and i have asked drew at Roverdose to build the engine.....

Engine spec will be as follows

DKE 79.4mm Forged Crank
Wossner Pistons 80mm (but i have some 82mm so we will see)
Wossner custom Rods
VVC Head, ported and polished 32.4mm inlets 28.5mm exhaust
Paul Ivey Valves, double springs, caps and solid followers
Cams 270M Exhaust 285M inlet (may go custom or Newman PH2 will see)
Custom Equal Length 1 7/8" Exhaust Manifold T25 flange
GTX2860 turbo
Siemans 660cc injectors
AP Racing 220 Turbo clutch (good for 300lbft)
W4 Uprated PG1 steel caged with Quaife Diff
Charge cooled (more likely a custom Pro Alloy)
Vibratechnics uprated engine gearbox mounts
DTA Pro S80 with traction and launch control

Going to go for 350bhp + will be happy with 300bhp but we will see what happens

Suspension and Brakes will be uprated to suit, yet to decide but we will see

Front damage, its missing the front crash structure, now bonded on



Front damage, its behind the clam so not an issue



Driver doors, need some repairs



DKE Crank, of unknown origin...79.4 stroke (we hope)



82mm forged pistons



after a day at cheeky scotts







 
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#93 ·
Well the good news is.........

Its on my drive, tucked up nicely in its new pyjamas ;)

Drove if home and it's geo is all over the place, the brembos rattle, the shocks are set too hard, suspension is too low, oil leak drops onto exhaust manifold which is leaking.........body work needs some flatting polishing and a few chips from fitting.

but its on my drive and third gear with foot to floor is a giggle exhaust sounds lovely too :)

Photo when it was light....its all together now

 
#94 ·
A big smile is an understatement ...

Nearly finished it off today. Still needs some flatting and polishing and grills adding. I am missing the front undertray so cant fit the splitter which is a shame.

111S Stickers to go on to but just so excited I couldnt help but put photos up

its booked in with Sportomotive on thursday for a Geo, going to go for 340r setup at 120mm front so I can go over speed bumps

had a little play on the way home and a nice man and his Pillion on a motorbike Aprillia Rv4 assisted with the how quick is it test......on low 11psi setting it was close thing.....so I would say its quick enough ;)




 
#98 ·
Woo hoo it has electricity ! Been a nightmare, battery had been going flat over night so thought the alternator was gone then it kept blowing fuses, 40amp. So had the alternator refurbed, this then blew the voltage regulator and the diode pack. So bought a new alternator that was the wrong size so old one refurbed again is back in.........phew


Dont know for how long but it managed to get to the local track for a quick blast up the straight, did a 3rd and 4th gear on low 11psi boost

You can hear the exhaust manifold blowing and its a little laggy, also ECU light is linked up to the DTA and comes on when its time to shift



http://youtu.be/Jckt3hODYFk
 
#99 ·
Currently sat in Sportomotives Reception with the car on the ramps, they very kindly booked it in at short notice
Not quite gone according to plan as the castors are out on the front and the worst wheel is the front right which had the crash damage, no surprises. Little bit of bonding on to the left of the right top wishbone which i assume was done after the crash is not the usual bond.
Rears were a little out too.....
Also fitted the Uprated Rear Toe Links but, and no surprise, as the car is a late 2005 it turns out it needed the taper bolts not the older style ones which came with the kit.



 
#104 ·
Well after the Ported Head i purchase was a dud, i decided to go all gung ho and get a new head ported by Jason Hellier of Hellier Performance as he is 20 mins from my house and i have heard good things about him. He is also good friends with Rog from Sabre heads and i would like to thank rog for his help.
Anyway, i asked for Jason to Flow Test the new head, the old cracked one (supposedly a GBE head, but its not) and the std head to see what flows i would get. The cams i have are 260 degree 285M Piper re-grinds with just under 10mm lift so figures at 400 thou are roughly this.
The std head flows ok, the cracked head did well on the inlet but basically bugger all improvement on the exhaust even though massive amount of metal was removed. Luckily Jason spotted this and his head flows approx 20% more than the std head on the inlet and exhaust so i cant complain. All test were done on the Janspeed Flow tester in CFM
Cams were set up and measured, took a day apparently, single piper springs (157lb @ 10mm vs 128lb std springs) with modified std caps for a 7500rpm limit.
But i now have a solid tested head so i hope this helps with the lack of top end revs.
Car is with JDM Dyno in Cumbria who will strip the head and re-dyno with a few other minor mods










 
#110 ·
Never apologise for a thread hi jack ;)

Well the head is off and new head going on tomorrow

Looks like the old head had been ported slightly

Exhaust manifold was warped, its been skimmed and ready to go back on

Oil leak was not what I expected. The cam carrier was leaking, but small amounts. Main problem was it was coming out the dipstick straight onto the exhaust manifold....so will add a couple of breathers.

Should be on the rollers on Friday for 400bhp........
 
#111 ·
Good news is that I was kindly sent me an S2 wishbone to compare with the existing one and it was slightly longer than the one fitted, so seems you the wishbone was an S1 item hence not being able to get negative camber

Bad news is that the original cams in the engine may not have been the piper 270 ones as they are not stamped by piper on the end. But this will be good news as the cams could be std so happy with the power it was making esp as the head only has a light port

Car will go back to Sportomotive to have the Geo corrected properly. Will then drive it for a few weeks and see what its like, then next year take it to one of the know how guys and get it setup how i want it. Secretly hoping the 340R settings will be good enough though :nana

Hoping the dipstick oil issue is windage and oil levels but its a worry as its a strange one, but it should be on the rollers this afternoon may even get a couple of power runs and hopeful to go over the 400bhp possibly slightly more if the engine will rev to the 7500rpm i would like :bc
 
#112 ·


This is what happened today.....low boost is 11psi so spot the problem ;)

Looks like the std garrett wastegate is too small and now I am getting more flow through the head it just cant cope so backed out at 6000rpm.

Still 360bhp but at 19psi so really have no control ovet boost

So ordered an external wastegate and will get this fitted next week.
 
#116 ·
Been a bit of a struggle to get things fitted

External wastegate needed to be plumbed into the water system as it was literally surrounded by exhaust

Anyway set point of 1 bar and it did the below, with a nice flat curve



Then set point of 1.63 bar and progressive boost control, it did the below, squiggle is wheel spin



On monday we will take the cat off and run it at 1.8 bar for a giggle ;) but will run it at 0.9 bar on the road with the cat and just de cat for the track as its all v banded in

So all in all quite happy and at 850kgs its 470bhp/tonne
 
#117 ·
Well just home, wife kicked me out of bed as cant sleep so might as well do something useful

So drive back from JDM Dyno was 365 miles and car drank approx 45 litres of 95 ron petrol which i calculate at roughly 37mpg....manly motorway driving with a few ahem spurts. Happy with that

Few issues though

1. Dipped Beam Headlights are terrible, I heard rumours they were pants but my gawd
2. Windscreen wiper stops where it likes on inter wipe, and stops completely on high speed
3. AP racing pads rattle, i understand this is normal
4. Fifth Gear is pain to select
5. I have a Kestrel Kevlar Clutch, fairly new and they are supplied raw and need bedding so clutch is / has slipped
6. Could get the clutch to hold on the Dyno, we thought it was wheel spin but i had clutch slip on way home
7. Its loud in the cabin, i thought 111S' were quieter lol

All in all i am very happy with the car, 80mph is 18% TPS 50mph is 6% probably needs a little more mapping below 2500rpm but for now its fine.

Manage 6 hours, ears arent ringing but blown a speaker.

Had to fit an aerocatch for the boot though, not sure if it looks right right but its a fix i had to do

AIT temps at motorway speed sat nicely at 13C, highest on Dyno after third quick run was 45C

And best bit, she is quick, very quick only had it on low boost 0.9 bar but its mental and i had no traction issues so either i am amazing, the diff is working or the traction control is doing its job. Must be the first one

De-cat spooled a little quicker, and made 30bhp more at 1 bar boost 356bhp vs 321 so in theory its good for 450bhp (my story and sticking to it in the pub). video you can hear the slippage

http://www.youtube.com/watch?v=LkjAxMpnSOg

Dyno printout of run




De cat Pipe V banded in



Larger Naca Ducts Fitted to undertray



JDM Dynos own built Mk1 escort, 2.9 V6 Cosworth (from the Scorpio no less) 350bhp 1/4 mile of 12.4

 
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