Elise - retirement project

[stratosboy]

So after 35 years service in the NHS, mental health care, I need something to fiddle with!. - especially as Zetec Elan project is sold.
Therefore decided on an S1 Elise rebuild project (with a difference!).
bought a nice 99 Azure blue one in the summer, a lovely thing, but high mileage and in need of a refresh. Great drive home with it though, ran well. I've never driven one before and really liked it.

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1st job - strip out and sell off bits I don't need. So seats, wheels, roof, engine/box, induction kit, clams, engine cover, roll bar, shocks, exhaust all sold.

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(I have some bits still available: ECU, aluminium uprights, drive shafts, brake discs, various trim bits, CAT, roll hoop cover, radiator, fuel pump)

new motorsport clams, roof, engine cover and spoiler to go on:

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2nd job - fit 6 point roll cage, tricky but pleased with it:

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more to follow....

[stratosboy]

mmmm don't know why my pics are not happening. I'll try again later.

[mill]

Can’t see the pics but sounds like it’ll be some weapon!

[whitergb]

7th job - fit traction control to keep it on the black stuff!

[stratosboy]

3rd job - suspension refresh:

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4th job - engine build: - I'm going with a charge cooled VAG 1.8turbo (although stroked to 2.0l) with big turbo installation. 6 speed box.
baffled sump -

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modified inlet manifold -

Elise stripdown August 2017 125.JPG (58.02 KiB) Viewed 14735 times

charge cooler -

Elise stripdown August 2017 133.JPG (74.19 KiB) Viewed 14735 times

more to come....

[stratosboy]

5th job brakes: I've got new 308 discs all round, front AP calipers are going on the rear, with spot calipers for handbrake. Caparo 4 pot calipers up front. New larger bore master cylinder fitted for 4 pots.
pics to follow.

6th job cooling: new Pro Alloy 3 pass radiator, with twin fans, and Pro Alloy charge cooler rad to go in. Silicone hoses all round -

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Elise stripdown August 2017 138.JPG (71.67 KiB) Viewed 14735 times

7th job traction control to keep it on the black stuff!

some other bits to go in: Tilletts -

Elise stripdown August 2017 148.JPG (76.61 KiB) Viewed 14735 times

coolant tanks for fitting onto bulkhead where rear window used to be -

Elise stripdown August 2017 135.JPG (66.93 KiB) Viewed 14735 times

more to follow...

[Nathan]

Wow! Sounds like a great project, hope some day I’ve got the time/money/space to start a project like this. Well done, keep the posts coming!

[stratosboy]

some more progress, first trial fit of body panels, lots of fettling yet to get them right, but I like this bit
suspension fitted too:

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[stratosboy]

a few more jobs done:
original Stack readouts are not that good, so added some extra Stack gauges where the radio and heater used to live:

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and drive shaft build up under way:

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[stratosboy]

6 speed VAG gearbox, cleaned and ready to go on when engine returns from builders:

Elise stripdown August 2017 137.JPG (79.62 KiB) Viewed 14626 times

and 60L Pro Alloy fuel tank with central collector fitted this weekend:

Elise stripdown August 2017 140.JPG (41.66 KiB) Viewed 14626 times

[whitergb]

Looks great, keep the posts coming.

[stratosboy]

bit more progress today, Pro Alloy triple pass radiator and charge cooler radiator fitted:

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needed a couple of minor mods to radiator shroud, to make it all fit.
Brake master cylinder is larger bore, for use with 4 pot calipers at front.

Drive shafts finished now and ready to go in,
Engine is being rebuilt, and due back in a few weeks

I'll post more when engine is being installed and new mounts fitted.

[Thommo]

More, please!

[stratosboy]

ok, some small bodywork developments this weekend, lights and mesh fitted:

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Colour is going to be Porsche Miami blue....I know, it shouldn't have anything Porsche related at all, but it is a fantastic colour.

Carbon engine cover coming this week, will post some pics when I've cut he louvre's out.

[whitergb]

This is shaping up nicely, what do you envisage the performance figures to be?

Good choice of colour

[stratosboy]

Thanks,
I'm hoping it will be quite quick! - my engine builder is aiming for 500bhp. but for it to be as driveable on the road, as possible. They are a VAG engine build specialist and have experience of getting over 1000 bhp from the 20v engine. I'll be using it mainly as a road car.

I don't know if you can see from the clam pics, but the clams are wider than stock S1 Exige, by 50 mm each side at the rear and 20 mm each side at the front. This will enable wider wheel fitment. I'm looking to fit 18 x 10 rears and 17 x 9 fronts.

I picked these up today:

Scroth Harnesses.png (250.76 KiB) Viewed 14159 times

and need some advice for their fitment to Tillett B5 seats. (I have Tilletts online guide) - I'd like to keep the OEM seatbelts for convenience. So want to fit these too. Has anyone done this and can help with some advice? - I have Tillett's EB1 seat brackets, and not using the original seat runners. Cheers Dave

[stratosboy]

some progress over Christmas/New year, rear discs and brakes built up and trial fitted:

needs a bit of fettling yet, caliper is very tight fit, needs shimming outwards slightly.
these are 308mm AP discs.

[stratosboy]

oops! did you spot that I've fitted my first disc (rear) on the wrong side?
corrected at the front:

left:

right:

[stratosboy]

good day in garage today, cut out the number plate recess to aid hot air venting. I will mesh behind to add some more strength back

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fitted new longerons:

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and then the rear clam quick release kit:

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[stratosboy]

having problems posting pics on here....will keep trying.
New longerons fitted:

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and yes I know I have some goggly eyes looking at me out of the subframe!!

[stratosboy]

seems to be only letting me post one pic each time:
here's the quick release runners fitted on top of the new longerons:

[nelly111s]

I've tried altering the settings - it should let you post 6 pictures per post, so you could try again.It's maybe another limit somewhere that I reset by mistake in the forum rebuild.

Nelly

[stratosboy]

cheers Nelly, seems to have fixed it.
so more of the longerons and quick release kit:

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quick release runners:

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got cut to pieces fitting these yesterday, the edges of the longerons are incredibly sharp, I kept wondering where all the blood was coming from!

[stratosboy]

oops no it hasn't...looked ok in the preview, but still not allowing more than one pic through!

[nelly111s]

It might be the size of the images. They look like they're about 12MB and 4000x3000. Try reducing the size (to about 3 or 4 MB) by either reducing the dimensions or compression. Try a 2000 wide setting and see if you can post more then.

Nelly