Shoofin's Lotus Exige S Thread [Update - P.11]
04-07-2013, 08:15 PM
#162
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Started the teardown for the clutch/flywheel replacement. Went with an ACT HDSS clutch, and Comp Clutches Lightweight flywheel. By far one of the most tedious jobs I have ever done on a car. My friend and I spent about 8 and a half hours and still haven't finished the job. We did manage to get the transmission back in, but need to put everything back in. In a nutshell, we had to remove the intercooler and airbox out so we can get to the top of the bell housing and starter, and that followed removing the entire driver side suspension, part of the passenger side suspension, pulling out both axles, disconnect most components, pull the engine off the motor mounts to tilt the engine a little so we can wiggle the transmission out of the very little space there was to do ANYTHING. Trying to get most of the stuff out of the way from now so I don't have to take it apart again. Also changed the brake lines with SS, but the passenger's side is next to impossible to get to, even with the clam off, so I'm going to have to grind down a little of the fiberglass around it to get to the nut to loosen the OEM line to get the SS line on. The rest of the corners have been done already.
Other things I decided to do as well:
-While taking the interior out to get the harness bar in, figured I would Dynamat some of the interior to help quiet the road noise. Also replacing the speakers in front and back, and eventually a new head unit.
-While I have the IC out and can access the airbox, will probably upgrade that.
-Sometimes the fact that it hasn't been driven for such a long time and it has low miles as a result, isn't always a good thing....I'm having problems with air in the fuel tank, causing the OBD2 to throw a few codes, which are suggesting that the vapors aren't properly being filtered through the tank. I can access the Charcoal Canistor while the IC is out, so I may just change it in hopes that it solves the vapor issue (CEL Codes are P0444 and P0446, both having to to with the Canistor and Surge Tank).
I was going to wait to buy a suspension, but figure with the front clam off, now's the best time, so I'll order the suspension tomorrow to get it on the car together with everything else.
There's a few other things too, Just too tired to think about it...
Suspension removed from the driver's side
Transmission out of the car
ACT clutch and Pressure Plate
New Flywheel in:
Other things I decided to do as well:
-While taking the interior out to get the harness bar in, figured I would Dynamat some of the interior to help quiet the road noise. Also replacing the speakers in front and back, and eventually a new head unit.
-While I have the IC out and can access the airbox, will probably upgrade that.
-Sometimes the fact that it hasn't been driven for such a long time and it has low miles as a result, isn't always a good thing....I'm having problems with air in the fuel tank, causing the OBD2 to throw a few codes, which are suggesting that the vapors aren't properly being filtered through the tank. I can access the Charcoal Canistor while the IC is out, so I may just change it in hopes that it solves the vapor issue (CEL Codes are P0444 and P0446, both having to to with the Canistor and Surge Tank).
I was going to wait to buy a suspension, but figure with the front clam off, now's the best time, so I'll order the suspension tomorrow to get it on the car together with everything else.
There's a few other things too, Just too tired to think about it...
Suspension removed from the driver's side
Transmission out of the car
ACT clutch and Pressure Plate
New Flywheel in:
Last edited by Shoofin; 04-07-2013 at 08:19 PM.
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04-07-2013, 10:21 PM
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I want to hear some videos
04-16-2013, 01:57 PM
#165
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Finally got most of the parts needed...
How she looks right now:
Catch Cans:
Nitron Singles Coilovers:
Harness Bar, Schroth 4 Point Harnesses, Tow Hook, Fire Extinguisher and others...
I hope to get her back on the ground this week!
How she looks right now:
Catch Cans:
Nitron Singles Coilovers:
Harness Bar, Schroth 4 Point Harnesses, Tow Hook, Fire Extinguisher and others...
I hope to get her back on the ground this week!
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CCColtsicehockey (04-16-2013)
04-16-2013, 02:06 PM
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man am soooo eager to hear some videos.....looks SICK
04-16-2013, 03:07 PM
#167
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Just amazing!
04-16-2013, 03:10 PM
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Wow! Making excellent progress! So many parts at once! 
04-19-2013, 04:51 PM
#169
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Slowly progressing...Putting the engine bay back together...Changed out the OEM filter for a K&N Element, installed the catch cans, and changed the plugs to Denso Iridium's. I hope to be finished in the next week or so...
Exhaust is in:
Also added Dynamat so I can hear myself think when cruising:
Exhaust is in:
Also added Dynamat so I can hear myself think when cruising:
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ttribe (04-19-2013)
04-22-2013, 03:53 PM
#171
thanks for the updates inspector... i think you should have gone with copper plugs though... the car should only require Iridium for long interval plug changes... with limited use, the copper plugs will last you 20-30k miles and you should be able to squeeze more response from them... they are cheap enough, i change the whole set with my annual oil change..
FI, maybe even get 1 step colder? that is what alot of the MR2 guys are doing with the 2zz swap...
FI, maybe even get 1 step colder? that is what alot of the MR2 guys are doing with the 2zz swap...
04-22-2013, 10:42 PM
#172
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thanks for the updates inspector... i think you should have gone with copper plugs though... the car should only require Iridium for long interval plug changes... with limited use, the copper plugs will last you 20-30k miles and you should be able to squeeze more response from them... they are cheap enough, i change the whole set with my annual oil change..
FI, maybe even get 1 step colder? that is what alot of the MR2 guys are doing with the 2zz swap...
FI, maybe even get 1 step colder? that is what alot of the MR2 guys are doing with the 2zz swap...
Bled the brakes and clutch today...I didn't know the clutch shares the master cylinder with the brakes...interesting...
Me pumping while my buddy was bleeding (he was doing the right rear in this)
And I'm happy to say, after almost 1 month since I parked her up to start working, she fired right up, and everything seems to be working as it should.
The annoying part of it all, I bought a few OEM Lotus items to correct the potential CEL codes that the car's been throwing related to the Evap/Emission system. 2 small parts cost me about $360, and I can't return it. Before I can install it but after I picked it up, we were tracing the lines to see where these parts need to go, and realized the connector to the purge control valve was disconnected (One of the codes = P0444 - EVAP Purge Control Circuit No Signal). Methinks the CEL was nothing more than a disconnected plug. When I fired her up, the CEL was on. Shut her down, reset the light, then the 1/4 tank of fuel in the car was now reading having no gas, and the low fuel light was on, just as I noticed my friend was holding the fuel cap in his hands, and the tank spout was open while I was idling. Shut the car down again, screwed back the fuel cap, started it up, and the gas was reading normal and the CEL didn't turn back on. I do need to drive the car a little first before confirming that the CEL won't come back on, but at least we're on the right track!
Also drained the oil and removed the oil pan, as I'm also adding a baffled oil pan too.
Lastly, I got my wheels back. Fixed the bulging barrel on the one wheel, had them re-powdercoated, and added an orange accent pinstripe to the edge of the lip, which will all fall into place once I add the orange accents to the rest of the car. Also painting the calipers a (hopefully) matching color orange. Ordered it online, fingers crossed that it's the right orange...
Looks yellow here, but look at the wheel in the left corner, the stripe looks a little more orange. Though they are all the same, the camera threw off the color a little..
04-22-2013, 10:55 PM
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Awesome Eddie! Congrats sir.
04-23-2013, 07:46 AM
#174
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Awesome update. I bet you can't wait to get her back on the road.
04-23-2013, 08:45 AM
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GREAT UPDATE !!!!
OHH I am in love with this car....
04-23-2013, 09:21 AM
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I'm happy that every time I open this thread, you have some kind of update and pictures.
Excellent work, I'm excited to see it all back together.
Excellent work, I'm excited to see it all back together.
Agreed. Can't wait to see her all back together...
04-23-2013, 11:31 AM
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how much weight did the dynamat add? that would be my only concern.
04-23-2013, 11:49 AM
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Figure I need to lose weight anyway, so the weight I lose will offset the added weight of the Dynamat 
I didn't use that much, but figure I might have added about 10lbs to the car. Then again, I am changing components of the car with a lighter counterpart, so I don't think the Dynamat will make a difference as far as hampering performance.
Here's what she looks like w/o the oil pan...
I didn't use that much, but figure I might have added about 10lbs to the car. Then again, I am changing components of the car with a lighter counterpart, so I don't think the Dynamat will make a difference as far as hampering performance.
Here's what she looks like w/o the oil pan...
04-24-2013, 04:47 PM
#182
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Thats not as loud as I expected. Sounds great though 
04-24-2013, 05:43 PM
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I would have thought it would be louder....But I love how it sounds....has a nice deep tone and ZERO rasp...
04-24-2013, 06:13 PM
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It's a "Track" exhaust, to keep within the limits of certain tracks that have sound limits. It's definitely louder in person, no question...
She's finally on the ground...Although I put the suspension on without adjusting anything, so this is how they company sent them to me, and it's so low, I can't roll it off the arms of the lift...Height looks badass though, but it's a shame I can't keep it this low, that would be a disaster waiting to happen...
The front is significantly lower than the rear right now....
I'll hopefully get her off the lift and drive her around a little to make sure everything works...
She's finally on the ground...Although I put the suspension on without adjusting anything, so this is how they company sent them to me, and it's so low, I can't roll it off the arms of the lift...Height looks badass though, but it's a shame I can't keep it this low, that would be a disaster waiting to happen...
The front is significantly lower than the rear right now....
I'll hopefully get her off the lift and drive her around a little to make sure everything works...
04-24-2013, 08:21 PM
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haha been there before where you cant get the car off the lift....
you need blocks of wood bro
I am digging this full build...eager to see more videos and some action...
you need blocks of wood bro
I am digging this full build...eager to see more videos and some action...
04-26-2013, 11:04 AM
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First Test run!
<iframe width="560" height="315" src="http://www.youtube.com/embed/D-ehZt1W_q8" frameborder="0" allowfullscreen></iframe>
<iframe width="560" height="315" src="http://www.youtube.com/embed/o_o1bL-ucZY" frameborder="0" allowfullscreen></iframe>
<iframe width="560" height="315" src="http://www.youtube.com/embed/D-ehZt1W_q8" frameborder="0" allowfullscreen></iframe>
<iframe width="560" height="315" src="http://www.youtube.com/embed/o_o1bL-ucZY" frameborder="0" allowfullscreen></iframe>
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juniorbean (04-30-2013)
04-26-2013, 11:55 AM
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Sounds great Shoof and damn it looks FASTTTT
04-26-2013, 01:10 PM
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Soooo I got back from the first run to the car leaking a LOT of engine coolant. One of the hoses were a little loose. The clutch is really grabby, I'm assuming it needs to wear in a little bit. However, I did read up on people saying the clutch will chatter a little if you don't give it enough throttle, and I tend to feather the throttle on the initial neutral to first take off. Dude in a Camry SE V6 tried to race me 
but uhhh, 
. Went back to the shop, tightened all the hoses. The CEL came back on again in the first run too. I plugged in my scanner, and it no longer was throwing P0444, which was the solenoid connection that we realized was loose, but it was still throwing P0446. I reset it again, and went for another ride. Drove to my friend's shop, stayed there for about a half hour while the car was running, shmoozing with him, and got back to the office. No leaks, no problems, CEL light didn't come back on. So far so good!
but uhhh, . Went back to the shop, tightened all the hoses. The CEL came back on again in the first run too. I plugged in my scanner, and it no longer was throwing P0444, which was the solenoid connection that we realized was loose, but it was still throwing P0446. I reset it again, and went for another ride. Drove to my friend's shop, stayed there for about a half hour while the car was running, shmoozing with him, and got back to the office. No leaks, no problems, CEL light didn't come back on. So far so good!
Last edited by Shoofin; 04-26-2013 at 01:13 PM.
04-26-2013, 01:38 PM
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