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Exige V6 Demonstrator

Being able to evangelise about how good some of our upgrades are, is one thing, but being able to let you experience them for yourself is definitely another.  With this in mind, a few months ago, we were able to procure an Exige V6, with a view to creating a demo car to showcase some of our favourite upgrade products.

The base car is a 2014 Exige S Roadster – supplied to the previous owner from new, specified with the factory premium and race packs.  The car already had the Komo-Tec EX390 upgrade kit installed a couple of years earlier, and whilst it had been used as these cars are intended, the car was well maintained (by us!), and performed as well as any example.

After a few months of developing the car, it currently has the following upgrades:

Komo-Tec EX460 chargecooled engine power upgrade

The ultimate proven and reliable power upgrade for the V6 has to be experienced to be believed.  Perfectly docile in normal road driving as well as supercar-slaying on the track, the EX460 delivers a significant increase in useable power and torque from lower engine revs right through to the limiter.  The stainless steel Komo-Tec manifolds and sports catalyst are specifically designed, providing optimised gas flow. The addition of the chargecooler system provides a significant reduction in inlet temperatures, allowing more power to be safely released from the engine by the ECU.  This is a particular advantage on track, where the chargecooler allows the engine to deliver all of the power, all of the time.

JRZ one-way adjustable suspension

We have developed the JRZ dampers for Lotus applications over a number of years.  Winning the Lotus Cup UK Championship in 2015 with the Elise Cup R, and their continued success that rivals struggle to match, has proven the track credentials of this upgrade.  However, they are also able to deliver outstanding road manners, handling poor road surfaces with excellent levels of comfort, which is something that is rarely achieved at the entry-level of the aftermarket damper market.  This is something that really has to be experienced first-hand, so was high up the list of things we wanted to do to this car.

With some additional work on our 4-wheel alignment rig to fine-tune the suspension setup, we now have a car which handles and drives in-line with our philosophies, both on the road and at the track.

Reverie carbon fibre aero and styling

We have been working closely with Reverie for over 15 years. The quality of their carbon fibre products is second-to-none, which is why they also produce sub-components for numerous high-end OEM vehicle manufacturers.  Since the car started out as a roadster, it did not have either the factory front splitter or rear spoiler.  We now have fitted the carbon fibre high downforce adjustable rear wing, which is mounted to the engine cover via colour-coded CNC aluminium swept wing mounts.  The wing is complemented by the extended front splitter to balance the aerodynamics and finished with track-spec front canards to aid turn-in.  The replacement side scoops carry the carbon fibre styling from front to the rear of the car.

Pagid RS-14 and Castrol SRF braking upgrade

The car was due for some replacement brakes, so we have retained OEM brake discs, but added the Pagid RS-14 uprated brake pads.  With improved performance at higher temperatures, whilst still retaining good road usability, and longer life without excessive disc wear, the RS-14 provides a cost-effective first stage brake upgrade.  In conjunction with Castrol SRF motorsport brake fluid, which is able to withstand significantly higher temperatures and superior resistance to the effects of absorbed water than a standard brake fluid, the consistency and reliability of the braking system is much improved. Moving forwards, the Komo-Tec KoBra brake upgrade would represent the next stage of this development, giving more heat dissipation and durability for hard-core road and track use.

 

As well as working as a demonstrator, we also use the car for new and existing product development, and as such already have a couple more upgrades coming to the car soon:

ECUmaster EMU Black programmable ECU

This exciting new product replaces the OEM ECU with a fully-featured programmable ECU.  With a bespoke engine map, this will allow the engine to be tuned to perfectly match the upgrade parts that fitted.  The additional advanced features of the ECU will ensure that the engine runs fully optimised whilst retaining engine safety. We will then be using this to setup bespoke tuned DPM stability and traction control modes, and configure full data-logging capabilities for the car.

H111 Gearbox Cooler Kit

Our own developed gearbox cooler kit helps the gear synchros to work more effectively at higher gearbox oil temperatures, specifically when on track.  This improves the gear shift quality and speed, in turn reducing gearbox and clutch wear.

Signature SV Exhaust System

Currently in development, we have a new range of sound-tuned exhaust systems which are definitely not track friendly! The Signature SV Exhaust for the Exige V6 will be second in-line after the 2ZZ and 2ZR systems are completed in January. More news on this in the new year.

 

If you are considering upgrades for your car, such as the Komo-Tec packages for V6 cars, the JRZ suspension (all cars), Reverie carbon and would like to see or experience the car, please give us a call to discuss.

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December Newsletter

You can read our December 2017 newsletter here.

 

 

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August Newsletter

Here is a link to our August 2017 newsletter.

 

 

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May Newsletter

Our May 2017 newsletter is here…

 

 

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Signature QT V6 Exhaust

Introducing our latest exhaust system development in the shape of the Signature “QT” (Quiet Technology) systems for the V6-engined Exige and Evora models.  The exhaust is a direct replacement for the original (or aftermarket) rear silencer and should work with any manifold and link pipe (“Y Pipe”) combination.

Many owners are complaining that they are being asked to leave, or can no longer attend, track days and track evenings due to exceeding the drive-by noise levels for the event.  At the same time, ‘noisy days’ at UK circuits are becoming increasingly rare as circuits feel the pressure of increasingly stringent local government noise enforcements.

The challenge is to create a quiet exhaust system that will not only reduce noise without restricting flow, but is also durable for track use without need for repacking.  In April we completed the development, and our new system fits the criteria perfectly.

At Brands Hatch, under close scrutiny of MSV officials and staff, we successfully tested the prototype QT silencer fitted to an Exige EX460.  The drive-by noise limit on the day was 92dB.  The tuned Exige also features our Komo-Tec sports catalyst, large-bore manifolds and carbon CAI airbox.  The testing was carried out back-to-back with the original Lotus factory exhaust system.  The results speak for themselves…

— OEM — — QT —
Static Noise (Cold)* 96dB 95dB
Drive-By (Cold) 86dB 82dB
Drive-By (Hot) 95dB 84dB
Maximum 97dB 89dB

*Note that the static noise is best measured with the exhaust system hot.

Having an industry-accredited exhaust manufacturing partner has always been a benefit when we design a new system, and this is no exception.  All our exhaust systems are manufactured from scratch, to our own specific requirements, with no off-the-shelf silencers or pipes used during construction.  Exhausts and manifolds are flow-bench tested to check flow rates.  This gives us the freedom to develop a more advanced and effective product that is fit for purpose, designed, engineered and manufactured in the United Kingdom.

Based on customer feedback, the other models in our Signature range for earlier cars are compliant with circuit noise regulations.  Testing at our workshops and track-side aligns with this feedback – especially with Exige S models (2006 on) where our Signature systems achieve around 98-99dB static and around 89-92dB drive-by when hot.  We will be producing some of the Signature QT exhausts for more highly-tuned Toyota and Rover engined cars later in the year.

Signature QT V6 exhausts will be in stock in the new few weeks. More information and pricing will appear on the website once the first systems are in stock. In the mean time we think they will be very popular, so contact us to get your name on the list for one now!

Update: Video from our testing at Mallory Park.

Video of Signature QT exhaust in action on Komo-Tec EX460 Exige at Mallory Park

Update:  Before and after performance figures from a recent Komo-Tec EV4-460 Upgrade we carried out.

Signature QT Exhaust Comparison to Standard Evora 400 Exhaust

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Elise S1 Refreshed

April 2017 saw the completion of a long-term refresh project on a very special Lotus Elise S1.  The Calypso Red car was the subject of a thorough overhaul, tackling paint, interior trim, brakes, wheels, suspension and engine modifications.

The owner, Chris Brooks, attended one of our CAT Driver Training days at Millbrook last October, where we discussed all aspects of his Elise and his intended use for hillclimb and sprints events in 2017.

 

 

 

 

 

Front and rear clamshells were stripped, assessed and repaired or reinforced before being prepared for paint.  During the process a number of areas were improved, for example the wheel arch liner mounting points were re-made along with some diffuser fastener areas.  The top coat of Calypso Red returned all the panels to an as-new condition.  Of course refinishing like this wouldn’t be complete without replacing door seals, window waist seals, decals and badges etc.

 

 

 

 

 

 

All suspension components were dismantled and bead blasted to remove all signs of corrosion.  Once clean, they could be carefully inspected for perforation in case corrosion had penetrated and compromised the strength of the metals.  All parts were then subject to a multi-stage anti-corrosion zinc treatment and finally powder coated at high temperature to establish a satin black finish.  Re-assembly included new Lotus OEM bushes, ball joints, fresh springs and damper re-valving.  Geometry setup was carried out in line with Chris’ requirements, combined with some proven settings we have used in sprint cars in the past.

 

 

 

 

 

For another year of competing in the Elise, Chris opted for the traditional ‘petty bar’ roll cage that we have used in our Elise Trophy cars over the last 5 years.  Manufactured by Safety Devices, this certified cage has the added benefit of a removable diagonal bar that allows the car to be used for more general purposes if required.  Like all other aspect of the installation works on the car, the cage was carefully fettled and fitted, leaving the installation complimenting the interior nicely.  Chris brought his own race seats to which we matched the trim to his requirements.

 

 

 

 

 

 

Last stage of the project was a remap of the engine on our dyno where a few more BHP were found and throttle response at lower RPM was improved.  Using the Road Simulation programme on our dyno, focus was also placed on mid to full-throttle transitions to ensure that torque was smoothly delivered when required.

 

 

The icing on the cake?  Chris took the car straight to Harewood hillclimb the day after collecting it from the workshop, and achieved a first position in class – very well done Chris!

 

 

 

 

 

 

 

 

In Chris’ own words…

” Thank you and your amazing team for the transformation you affected to my year 2000 Elise S1 over the winter.

I am the 5th owner of the car and have now had it for 7 years. I bought it to use on the road and to compete in hillclimb events. Over the years I have made significant improvements to the car while trying to ensure that it fits both purposes. I have carried out some of the work myself (I am a qualified engineer) and have also used a good number of the suppliers & garages popular with the Lotus owners community. I can say without hesitation that Hangar 111 is the best outfit I have dealt with in all this time.

The car was generally in good order, but I wanted it gone through in detail to improve every aspect of it; ride, handling, braking, engine performance and appearance. From the very outset, Greg understood what I wanted to achieve and used his expertise and experience to develop a specification for the work to be carried out. It was a significant undertaking, taking the car back to the chassis, refurbishing and upgrading the suspension, brakes & steering, repairing and respraying the bodywork, refitting the interior, repairing a few oil leaks, timing the cams & remapping the engine. Inevitably, there were a few surprises along the way, like the loose pedal-box, but I was kept informed of the issues and consulted on potential solutions.

The result is astounding! It is like driving a totally different car both on the road and the track. I competed in my local hillclimb at the weekend and comfortably won my class, even though I am still getting used to the feel of the car. The work that you did on the suspension geometry and brakes, in particular, make the car far more confidence inspiring which means I can push nearer to the limits than I would have done previously.

I have already recommended Hangar 111 to a number of people – your knowledge, experience, craftsmanship and attention to detail are all superb and I could not be more delighted with the car that you have all produced for me. Thank you.”

We look forward to seeing more of Chris’ progress as he attends other events!

UPDATE: Chris won his class in the subsequent event!! Double Congratulations!!!

 

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