K-Series Cambelt Band Saw!

One of our local customers has kept his prized Elise S1 in totally standard form, clocking up over 109,000 miles using it almost every day (he loves it!).  The car has been regularly maintained and is usually given a clean bill of health every year, apart from the usual wear and tear items – wheel bearings, ball joints etc.  With about 3 weeks to go to the annual service, the car developed a vibration which the customer ignored for a few days then it developed into a louder rumble and then a clonk from the engine bay then the alternator charge light appeared on the dash.  The customer assumed the alternator was the cause so drove on, working on the principle that the battery would get him home okay. Unfortunately a few miles down the road, everything ground to a halt, and he called us to the rescue.

What we found was somewhat surprising… the crank pulley bolt and load washer were completely missing – that was the clonk.  In turn this caused the crank auxillary belt pulley to fall onto the undertray and the auxiliary belt to detach – that was the charge light.  The keyway on the cambelt pulley had broken, but the engine kept running until such time that the cambelt had sawn its way perfectly through the cover!  In all the years we have been a Lotus specialist, this is a first!

On removal of the head, 4 exhaust and 2 inlet valves were bent, however in traditional K-Series style the head was too soft to be re-used, coupled with the cylinder liners being at the lowest allowable protrusion.  This combination finally sounded the death knell for this trusted high-miler engine.  With the car in otherwise excellent condition, the customer is now going ahead with a fresh block build and one of our new heads, ported and polished to 150bhp spec.

Our diagnosis was straightforward enough, however the root cause may lie with the missing crank bolt and load washer.  The best thing we have to go on is that the auxiliary pulley has some of the rubber dampener missing and was no longer running true.  The dampener may have simply gotten old and perished, developed a vibration that led to the crank bolt coming loose over time.  Either way we are stocking up on auxiliary pulleys and crank bolts to be on the safe side!

You can sometimes see the start of a pulley dampeners demise before noises begin.  We check them by eye on the service with the engine running while we check the exhaust for leaks.  We’ve seen a few wobbly ones in action that neither chew nor throw belts, so I suppose it could be classed as a ‘silent killer’!


Rolling Road – Coming Soon!

It’s been a busy year so far at Hangar 111.  As we continue to grow we are adding new services all the time.

One of the new services that is going to be a significant addition is our Rolling Road Chassis Dynamometer.  Designed with all Lotus models, track-day and race cars in mind we are aiming for an Autumn launch where we will kick things off with an open day where you can come and take a look! As you can imagine, we are all very excited about this!

More news as it happens…..


Komo-Tec EV430 and EX430 Kits for Evora S and Exige

Hangar 111 are official UK installer of Komo-Tec tuning products for all Lotus models. We upgrade all models of Elise, Exige (S2 and V6) and Evora to give more power and torque as only Komo-Tec can deliver.

Our partnership with Komo-Tec spans over 10 years during which we have created some truly awe inspiring cars.

The latest upgrade for the Exige and Evora gives appx 430 bhp and 345lb/ft of Torque – giving these cars true ‘supercar’ dynamics befitting of their excellent chassis.

It doesn’t stop at the power however! The sound effects from the specially developed Komo-Tec 3-1 manifolds are unrivalled – giving amazing sound effects while retaining the ability to take the car on the track without tripping the noise meters (with the standard exhaust fitted).  The EX430 (Exige) and EV430 (Evora) kit is £4399 . Installation takes appx 3 days and includes a vehicle health-check before we proceed with installation.

The kits includes:

  • Specially Designed Stainless Steel 3 into 1 Manifolds
  • Single Ceramic Sports Catalyst
  • Wiring Loom Extensions
  • Carbon Fibre Induction Kit (“CAI”)
  • Modified Crank Pulley
  • Engine Management Reprogramming
  • All installation, setup and fuel testing

For those looking for a stage upgrade, we can also install the 390 and 410 version of the kit which are available for a lower cost. For more information please see the product pages HERE.


Lotus Festival – Brands Hatch Come & Say Hello!

The annual Lotus Festival will be held on the weekend of August the 15th  and 16th with the usual exciting mix of classic and modern Lotus racing, complimented by a parade of Lotus cars and trade stands.

We will be running our Lotus Cup UK championship leading driver in the pits, so why not come and say hello in between races.


Rover PG-1 Gearbox Synchromesh Upgrade

We are pleased to have in stock complete sets of new, upgraded synchromesh rings for the Rover PG1 gearbox.

Our new synchro rings feature a carbon lining to give maximum durability and smooth shifting in high temperature/high-load conditions. The rings are sold as a complete set and are a direct replacement for the originals.

If you are having trouble with your Elise, Exige or 340R PG1 gearbox, we can rebuild your box (including removal and refitting) here at our workshops. We have many new and used components for these gearboxes on the shelf.

The new synchro kits are available now from our webshop HERE


Elise Cup R – Racing with Hangar 111

Track preparation and support is only a small part of what we can do with your Lotus here at Hangar 111.  In the last 4 years we have been up at the front of the Elise Trophy and Lotus Cup UK series with carefully prepared Toyota and Rover engined production-class cars.  In 2014 we began running the supercharged Elise Cup R and continued our postion at the front of the grid.

Since it’s launch we have gathered more data and working knowledge of the Lotus Elise Cup R platform than anyone else in the UK.  We can provide cooling improvements, chargecooler upgrades, gearbox enhancements, suspension and setup to make the Cup R faster, more durable and better handling.   The proof is in the results!

The Elise Cup R is still available from Lotus Racing and are pleased to be able to supply and setup a new Elise Cup R for for the 2016 season.  This includes a free seat fitting and suspension setup here at our workshops.  The Elise Cup R is ready to race in the following wheel to wheel series and championships:

  • Lotus Cup Europe
  • Lotus Cup UK
  • Lotus Elise Trophy
  • 750 MC Cartek Roadsports Endurance Series
  • 750 MC The Birkett Silverstone 6 hr
  • MSV Team Trophy Mini Endurance
  • MSV Track Day Trophy
  • BARC Sports/Saloon Championship

The Elise Cup R also makes an excellent sprint/hillclimb prospect with it’s low-down torque and instant throttle response. Eligable sprint series include:

  • 750 Motor Club
  • Lotus Cup Sprint Series
  • Borough 19 Sprint Championship
  • BARC SBD Sprint Championship

Of course we can prepare and support your racing requirements in any post 1996 Lotus so get in touch if you would like to know more!


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