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Discussion Starter #1
Hello, i thought i would post this up as some entertainment for you all

I have a 2005 Lotus Elise 111S that was a Cat D, which i bought 2 years ago with a view to building a Rover K series Turbo.




I used to have a Rover 100 with a 1.4 Turbo K Series with just under 300bhp but wanted 400bhp for some unknown reason. The K series above 300bhp gets silly expensive, the 1.4 was about 10k to build, so i heard of someone fitting the T series and long story short made it 420bhp. But it didnt like oil, so one sunny day it rattled its big ends and basically went bang. Engine had less than 2000 miles and was the second T series i had fitted.



So i decided to sell the car and all its bits, came up with a figure and a nice local man said he'd pop round and have it. I panicked told the wife the bathroom was on hold and explained to nice man i had to make it work.

Rebuilding the T series would of been about £4500, but i was pretty certain it would hate its oil again (Engine is tight in Bay and on an angle cambelt to fly, oil pick up is by cambelt)
I looked at 2.3 DISI Mazda engines, but above 300bhp they start needing special bits and ended up being a £6000 build for the engine and aftermarket ECU
So thought 2.5 Duratec Turbo, but again its unknown what it can handle then pistons and rods were scarse and a forged engine was about £4500
I considered the ECOBOOST engine but an aftermarket GDI engine was silly money, £2500 ish plus a loom about £1000

All the above can be used with the PG1 box in the Elise, i have a Rover 620Ti gearbox installed good for over 400lbft

So i did what any idiot would do, i got drunk thought f*%k it and bought an ECOBOOST engine on Ebay for £1700 with everything on it thinking with the ECU and Loom i would be about £5000 so cheaper than the above........



The Duratec has been fitted to the Elise many times before and the ECOBOOST i was told had the same gearbox PCD so i bought some Adaptor plates off the shelf
They also recommended the Silicone Hoses kit, so it looked good (still not fitted to check so heres hoping)


I fitted the Adaptor Plates and Engine mounts, Top mount actually is ok, it has 2 bolt holes and the studs are too big but i can work with it.



The lower mount may not fit.



Adaptor plate is good



I then realised the engine had some balancer shafts, so googled delete and Mountune popped up with a modded Baffled Sump



Then i had a phone call from Specialist Components in Norfolk who are ex Lotus guys, Simon said that he supplied Zenos with their ECU's for the E10S and could supply and ECU and Loom for about £1800 and it would come with a 280bhp map and use all the std sensors and......i stopped him there and bought it

Ford 2.0 Ecoboost Management Kit - Specialist Components

I have 14 wires to connect and the 6 wires to the DBW Pedal, plus Simon has assured me he will give all the technical help i need (he so far is good to his word)




So this is where i am at at the moment

The goal is 420bhp, as this would be about 500bhp/tonne with a 840kg car (T series was 890kgs) so will be looking at either a forged 2.0 or a 2.3 RS Focus engine next year once everything is working
 

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How are you planning on handling the intercooler?
They usually sit either in one of the side pods of the car with scoops providing air or on top of the engine with a roof scoop. Since he already had a turbo engine in it it's probably already setup.


Sent from my iPhone using Tapatalk
 

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Discussion Starter #7
Thank you all, should be a giggle when its done

Intercoolers in the side pods isnt the best idea, they only really flow enough for about 240bhp (single intercooler) get a lot of heat soak and add heat to an already hot area

So the car is currently Charged Cooled with a full size rad at the front with the triple pass radiator

Managed to pick up a C4 K series Pg1 from my mate Tony, who has a magic shed with rover bits in it, cheap as chips and bolted it to the engine




I also spotted a decent sized chargecooler and Tony kindly let me have it for a good price. Will use this with the std engine and it's twice the size of my home made affair

 

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Discussion Starter #9
Test Fitting on the engine today





Was a little bit of a pain to go in, but removed a couple of sensors and with some giggery pokery she is in.

Cambelt engine mount is different from the Duratec (3 holes on ecoboost 2 on Duratec), but we should be able to use it. Main issue is height, but will put a shim under the chassis engine mount and should be able to get the engine nice and level.




Next is the Turbo, close on the inlet but the outlet hits the main chassis. Dont see this as being too much of a problem will be able to rotate it 45 degrees (New bracket for actuator) and should fit




Couldnt get under the car but the other issue was the Aircon Bracket hitting the drivers side water hose, should be able to get round this

Plenty of clearance on the pulleys even with the double crank pulley (supercharger)



Also the Oil Filter Housing was removed, looks like i will need to fit a remote filter which i already have



All in All, not a bad day out. Hopefully have a few more updates before Xmas

Gearbox is being rebuilt to a k series bellhousing and Flywheel has been ordered 4.25kg
 

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no idea what half the stuff he says means, i.e. "giggery pokery", however this thread is full of win in my humble opinion, I've seen some pretty fast lotus cars with Honda K series swaps, so an ecoboost swapped one should be extremely fun to drive. subbed!
 

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Sorry my spelling is awful

jiggery-pokery
nounBRITISHinformal
noun: jiggery-pokery
deceitful or dishonest behaviour.
I like it
 

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Discussion Starter #20 (Edited)
I have tried to keep this as English free as possible, but any slang not understood please let me know :p

Christmas came kinda early today, luckily the wife was out too ;)



Grant from GB Enterprises sent me a nice new 4.2kg lightened flywheel, this has been made for the PG1 box (std Elise) drilled to suit the T series (Rover 620Ti) Helix clutch i have (rated to 425lbft). Dual Mass flywheel is about 10kgs (no scales) so a decent saving. I even fitted the Focus clutch (its the same size as the T series), shame the PG1 uses a funny spline ;)





I wont be using the MMT 6 speed, and the Gearbox for the elise was a T series PG1. Good news is this is similar, t series has an additional bearing, to the K series PG1 which is std fit on the Elise. So this is with a great friend who is changing the bell housing from T series to K series and we are looking at reducing the final drive to 4.2 as this is similar to the MMT Gear ratio's 1st to 4th. Fifth being slightly longer at 23mph per 1000rpm which isnt too bad and i wont have a 6th speed. Gearing will be about 160mph which is plenty for a 850kg car made by Farmers from Norfolk with Aluminium and Fibre Glass ;)



Also hated the foam filter i had so bought a massive K&N Air Filter again from Grant




Please note the carpet wasnt my choice, its a new house and the previous owner was Scottish and Colour Blind (its for sale if anyone wants the carpet)
 
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