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Caught wind of this thread over on the LotusTalk site and had to sign up to subscribe. Can't wait to see the end result. I absolutely love threads like this!

BTW for us Americans, wtf is a fag packet? cigarette box?
 

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Discussion Starter #84
I now have the engine at home, I need to add in some oil and water pipes to the turbo and tidy up the breathers



JEK Fabrications made the exhaust manifold, oil return and also the brace which is rose jointed to allow movement due to heat.





I have also looked at the PCV breather and added in an oil pressure sensor (only comes with temp as std) and I need to seal all the joints



Then I need a TMAP sensor, Lambda sensor and stuck whether I ship it back to Specialist Components for mapping (where their normal dyno has a long waiting list) or book it in to make the engine mounts, get the engine running (2 month waiting list) on the std map and then drive to SC to have it mapped.

Ideally I ship it to SC and they get it back in 2 months and I get the engine installed but I don't think the way the project has run its that easy
 

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Discussion Starter #85
Wow, you go away for holiday and leave the car with a man and **** gets done.......why didnt i do this before

Anyways, engine mounts are now made and engine is in the car. Turbo hasnt been fitted but i see no reason why it wont fit

Drive shafts fitted all ok, no rubbing (unlike duratecs so i am told)












No idea what this lug is but seems to be ok



Wiring next ;)
 

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Discussion Starter #86
Got the inlet and the turbo on today

Looks like it was meant to be in there, lot of room for the turbo and inlet was fitted in 30 mins as it went through the inspection hole

Wiring is now being sorted and I'll plumb in the water and oil hoses when home





 

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Discussion Starter #87
The new fuel pump turned up today, big thanks to Gaz at Spitfire Engineering. This (small) pump should provide enough fuel for 500bhp at 3.5bar and Gaz kindly sent me a complete unit, i have to send my old unit back. I went for the Deutschewerks pump

This will save me a swirl pot, lots of fuel pipes and i dont need the Bosch Motorsport pump i had on the T series.




Hoping to have the car wired up to the ECU and Ford Loom next week
 

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Discussion Starter #89
Got the Elise out today and did some work at home



Put the engine cover on and it will be tight but the HPFP pressure sensor and the wastegate both it (when level) but need to get the rear clam on to check

I have the Duratec Silicone Hoses from Essex Autosport and tried to get them to fit. I got very confused until i realised the Ecoboost water inlet and outlet are on the opposite side to the Elise so after doing some searches (yes i know) of the Duratec builds i saw the swap of water pipes. With some pipework from the rover i managed to get it all set up

This makes it a little congested under the inlet, as the water pipes Swap over, the oil cooler water pipes, the remote filter pipes and the throttle body inlet.



Fitted the starter and it fouls the bell housing adaptor, bit strange but an easy fix



Also looked at fitting the fuel pump, and the hole is too small, i think i will go for the easy option of cutting the top rather than dropping to the tank (as no ramp)

 

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Discussion Starter #90
I think it's best to say my motivation with the car is waning, work, travel, family and work on the house have ground me down.

I cant even be bothered to fit some water hoses and sort out the vacuum......its got that bad.

So tomorrow the car is off to HPE Automotive in Bromsgrove for Dan to finish

Monday the engine is then with Specialist Components to map and see what she's got (if the turbo can give it enough air)......

Pick a power figure if your bored, I'm going with 400bhp at 11psi and 8000rpm for a giggle and 480bhp at 23psi and 7250rpm.

But today I suddenly realised I hadnt fitted the rear clam with the new engine in, and I was off to Germany at lunchtime

First fit didn't look too bad at the back



But terrible at the front



So I found the sabre saw and made it fit.



But it hit the wastegate(built when the engine wasn't with the car so can't complain)



I gave accepted I will be losing the boot so will fabricate, sorry asked Dan to fabricate something to lock the hatch too.

Boot will be exhaust as it was way too loud before
 

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Discussion Starter #95
Wow, you wait a whole year to post that..........thats some memory and slightly weird

Oh and for the record we saw gains with the larger injectors ;)
 

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Discussion Starter #96
Engine lasted 10 minutes on the dyno last week, then started to have a bad misfire at 2500rpm and load. So the head have to come for a re-check

Spoke to the Engine builder today and its pretty clear whats happened

The head was coked up so the valves were sticking.

An expensive lesson, yet again, but asked them to strip the engine, check and rebuild. They found a few minor issues and have mentioned that it may be worthwhile porting the head..........it never ends

Should be a couple of weeks to get it put back together
 

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Engine lasted 10 minutes on the dyno last week, then started to have a bad misfire at 2500rpm and load. So the head have to come for a re-check

Spoke to the Engine builder today and its pretty clear whats happened

The head was coked up so the valves were sticking.

An expensive lesson, yet again, but asked them to strip the engine, check and rebuild. They found a few minor issues and have mentioned that it may be worthwhile porting the head..........it never ends

Should be a couple of weeks to get it put back together
How many miles were on the engine you put in there? Haven't heard of anyone with buildup enough to cause issues like that yet.
 

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Discussion Starter #98
Mileage was 1500 miles, which doesnt look right

I havent wanted to "bother" the engine builder, Damico, as he is manic and fitting in mine between jobs for which i am eternally grateful

Luckily today he called and we had a chat so;

The engine wasnt missing, this is my misunderstood (i was in shock and at Duxford with my 4 year old). The engine was breathing badly, and it got to a point that they were not happy with so they stopped the dyno and advised the problem. With the leakage on the valves i asked them to strip and inspect the whole engine, as i knew the

The engine was coked up, see the photos below. As said this wasnt causing the engine to Misfire but was causing the valves to stick. The valves were sealing when the cams were removed, however they hadnt been lapped or cleaned. The engine just sounded sick and wasnt able to pull through the revs.

The piston rings were on the large side, but in tolerance, however the second ring had a larger gap than the first, all now being fixed

The head was in tolerance for flatness but only just, head is now being skimmed, de coked, cleaned and then ported. Sealing face wasnt as clean as Damico would of liked (polite for had gasket marks, same for the block)

The crank, and bearings, are all fine. Some evidence of a "dirty build" but all can be cleaned up and in tolerance

So I wasnt charged for the engine build (long story), but at least now i know its been done to the highest standards. I just hope the wife doesnt find the bills and this thing had better work !!!



 

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Throw some Mustang 30mm exhaust valves in there before they put it back together. They're cheap and the seat doesn't have to be changed just machined. It will help it breathe.

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