Projects
On a Saturday evening earlier this year, I stopped by the shop and unexpectedly saw an Evora in our parking lot that looked like it had been in an accident. I later received an email confirming this, and it had been towed in for an evaluation.
Over the 2023 winter holiday break is when things got really serious for our Pikes Peak car. We used the downtime to get a lot done, including a full rebuild of our Drexler rear diff.
It’s been over 3 years since I put the Honda K24 into our Lotus Exige and it was the first car that I made an engine harness for. Although the harness was reliable and never gave me any issues, I felt that my harness building skills have improved much since then. What I really wanted to do was get rid of all of the unused wiring and the mess under the dash.
Picking up from where we left off in Part 1…over the past few weeks we have continued to work on ensuring our BMW E46 M3 survives the thin-air and increased cooling demands of Pikes Peak. I sourced a KSR hood vent (thanks Ken) which is the perfect size to serve as a ducted exit for the v-mounted intercooler. We also added an inlet to the driver side carbon fiber lens to feed the hungry Active Autowerke Rotrex C38 supercharger.
Back in March, we announced our plans to tackle one of the most difficult motorsport events in the world; the 102nd running of the Pikes Peak International Hill Climb in 2024. In preparation for this grueling challenge; which will test us as a team, me as a driver, and the car we build over a distance of 12.42 miles and around 156 turns on the way to a summit elevation of 14,115 feet, we decided to spend the next year taking our time to thoughtfully plan for a successful race to the clouds. While my mental-state and physical conditioning are equally important, for purposes of Part 1 let’s just focus on what most people care about more…the car!
Before doing anything K-swap related to the new chassis, we started by transferring parts over from the original tub to the new one. Since this was a low mileage car, it wasn’t difficult selling the drivetrain. Timing worked out perfectly as there was another Elise in our shop needing a motor due to a failure.
Back in February of 2020, our longtime Lotus customer reached out about potentially building an Elise from the ground up. The idea was to build a car to his exact specs, a reimagined Lotus Elise. The plan was to buy a brand new tub chassis from Lotus and hand-pick, or fabricate, custom parts for one goal: his perfect “streetable” track day car. Most of the drivetrain and miscellaneous bits would be taken from his current 2011 Elise.
In part two of the K24 swap, we were left waiting for the header to arrive. We ordered a Hytech 4-2-1 header specifically made for this swap, which took a little over a month to get, but was well worth the wait! It fit perfectly. Other than trimming the J-pipe to length it needs no modification to fit any muffler designed for this chassis. Once fitted, all we had to do was make an extension harness for the wideband o2 sensor.
When we left off in part one of the K24 swap, we had the engine in the car and started getting things connected. Although it seemed like it was close to being done, there was quite a bit left to do. We decided to keep the factory dual oil coolers. This may change in the future, but we wanted to make sure the temps were stable even on extremely hot days. Moving along on the track is one thing, but following closely behind another car in “dirty air” and it can get hot pretty quickly. Because these cars are known to over cool engine oil, we installed a thermostatic sandwich plate with a 200F thermostat to help maintain proper temps.
If you grew up in the 90s and were into cars, then you’ve heard of the Honda B-series engine and how amazing it was. It was the “hot rod” engine of its time and my gateway into modifying cars. The planning, researching, parts sourcing, building, and then seeing how it improved the car’s performance is what got me hooked. In the early 2000’s, Honda came out with something even better..
In Part 8, we were waiting on a driver net before we could have the tech inspection done. The Schroth net with the new quick release mechanism that we originally ordered was still undergoing testing and its availability was severely delayed. So, we went with a equally good option- Safecraft.
With a year of rebuilding and developing the Exige behind us, we were excited to begin our “winter project,” the roll cage. When the car came back from the last track event of the year (a very wet Laguna day), we gave it a good wash inside and out before getting into it. We also had to do some homework and make sure that what we build is safe and legal for the the local sanctioning bodies we plan to race with. We followed NASA’s Club Codes and Regulations handbook as a guide.
At the last two-day track day at Buttonwillow with Speed Ventures, shifting in the Exige started to get notchy. It would sometimes be difficult to get into gear, but we kept driving it. By the last session of the day, we were not able to get the car into gear after pulling off into paddock. If the engine was off, it would go into all gears, so we suspected it to be a failed clutch that was not fully disengaging...
Fuel starvation is a well known problem with this platform. It’s mostly noticeable on long left hand corners because the fuel pick up is on the left side of the tank. It’s typically not an issue if I keep the fuel tank full, but every time our got down to about 70%, it would starve. This can cause a lean condition and be harmful to the engine, especially with forced induction.
The Exige S is known for heat soaking and extremely high IATs (intake air temps). The stock intercooler is mounted on top of the hot engine and doesn’t get nearly enough airflow through the small roof scoop. It also doesn’t help that the hot air from the radiator exits in front of the windshield and makes its way into the roof. There are some things you can do to help like a larger intercooler, additional ducting from the side scoops, larger roof scoops, or adding fans to the intercooler…
This past Monday, June 24, we decided to take a team day-off to go to the track with Golden Gate Lotus Club. In addition to drives, meets, and fun outings, GGLC hosts great track & autocross events. Only three run groups, so you get SEVEN sessions! Not to mention, they always offer snacks, coffee, fruits, and sometimes even lunch!
It’s no secret that Reverie makes high quality (wind tunnel tested) aero parts for the Eliges and I’ve always liked their front splitter design. Although Reverie’s mounting solution works great and is solid, I decided to attach the splitter directly to the chassis, and not to the front clam. My reason for this is so that I can easily remove the front clam without having to remove the splitter first. This did require cutting the front lower portion of it so that it could just rest on top of the splitter…
Following my crash at Sonoma last October I spent some time thinking about what I wanted to do next. I knew I wanted to continue racing with NASA in Super Touring because the ST4 class is growing steadily and we have great camaraderie amongst the competitors in the field. For a brief moment, I actually considered building another S2000 but realized after 9 years with the platform that it was time to move on and do something new. As such, in November we began tearing down what was left of “Irene” and selling any remaining/usable parts.
When we first acquired the Exige, Victoria and I had multiple conversations about what we wanted to do with it. Our original plan was to keep it street-legal, and just use it for canyon driving and the occasional HPDE events. I knew that it would have a much higher resale value if it was kept street-legal. Plus, being that this is our first Lotus, we liked the idea of being able to take it out every now and then. We also wanted to take it on long road trips and enjoy some of the fun back roads we have here in California. …Well, that idea didn’t last too long.
My first encounter with Lotus cars was when I was 18 years old and I signed up first my autocross in my 1996 Acura Integra with the Golden Gate Lotus Club (GGLC). I always thought they were “cool” looking and after going on a couple ride-alongs, I could already tell how fun it would be to drive one. ...
The Exige returned to Laguna Seca on Monday, August 27, to test a new aero setup! Trackspec removed the stock splitter, wing, and diffuser and replaced them with the Reverie 1650mm wing, Reverie front splitter, and Difflow Flat Track diffuser.
If you follow us on social media, you know that we recently acquired a 2001 BMW 330i sedan. The car has already gone through some major transformation in the last couple of weeks. We're not sure where this car's origins are from exactly (it probably spent most of its life driving people to and from work, or the mall)…
We left off in March after having just picked up our new (to us) J32A2 engine, and as promised we've been busy getting it ready for the demanding rigors of race conditions. We were thrilled to receive high-performance valves, springs, and retainers from my partners at Supertech Performance in order to do just that. These awesome parts allow us to rev the J32A2 engine well beyond it's OEM redline limitations, but safely.
Part 1: The Build. Why J-Swap? Last year, we finished 8th at Nationals and 2nd in the Regional Championships in Super Touring 4 with 212 average whp at 2,800 lbs; well below what the rules allow. Good results overall. But we can and want to do better.....
Sam approached me at our grand opening party about two years ago. He had just moved to California with an unfinished track-car project. He said it didn't have any windows, the cage needed to be finished, it needed seats mounted and a bunch of other random bits to put it back together. As I started to show interest in completing this project for him, he casually mentioned that the main wiring harness had been cut and the car would no longer start.
About a year ago, we were approached by the owner of this yellow Fiat X19. We set up an appointment so that he could interview the team who would be working on his Fiat X19 Honda K20 swap. After discussing our credentials and the logistics, the owner decided that we were the right shop for this project. We don't usually work on X19s, but I felt that it would still fit well in our shop since it's a light weight, mid-engine, sports car.
It’s been a while since we had an update on this car and a lot of people were starting to wonder what happened to it. Between the many obstacles to overcome, developing some custom parts, going back and forth on decisions, the owner of the car (and myself) having two having kids, this became a sideline project in the shop. Our usual chats shifted from the K20 swap to sharing our experiences raising two young children. Although progress was made slowly throughout, I wanted Part 3 to be the final part of the blog.