2007 Lotus Exige S

[turbotalon1g]

Looks nice.

[asshanson]

Exhaust and intercooler removed today. Started by taking the wing and hatch cover off:
http://www.dsmstyle.com/photopost/data/675/hatch_lid.jpg
http://www.dsmstyle.com/photopost/data/675/engine_bay_before.jpg

Goodbye evap!
http://www.dsmstyle.com/photopost/data/675/evap.jpg

Rear panel, undertray, and exhaust removed. Really surprised how clean the engine block is:
http://www.dsmstyle.com/photopost/data/675/rear_removed.jpg
http://www.dsmstyle.com/photopost/data/675/engine_block.jpg

Stock exhaust stuff that is crazy heavy for just being a muffler:
http://www.dsmstyle.com/photopost/data/675/stock_exhaust.jpg

After I got the intercooler off, here is how it sits now:
http://www.dsmstyle.com/photopost/data/675/engine_bay_bare.jpg

My muffler should get here sometime next week, it's supposed to be pretty quiet at low throttle, combined with the headers I think it will be a nice deep sound but still not drone on the highway.

[Goat Blower]

Wow, progress looks good! Now you need the widebody conversion being done over on MNSC. :D

[Halon]

Nice bling!

[rose0529]

nice work!

[asshanson]

Got the new rotors and rear wheel arch liners installed today. I really like the rotor design, the veins are pointing the right direction on both sides. Most rotors I've seen before are identical on left and right sides, meaning one of the them will be backwards once installed.
Before:
http://www.dsmstyle.com/photopost/data/675/wheel_well_1.jpg
After:
http://www.dsmstyle.com/photopost/data/675/wheel_well_2.jpg

Also got the passenger window rattle fixed, and hope to have the exhaust installed this weekend.

[PlanoEvo]

Most badass indeed!

[s1ngletracker]

http://blipshift.com/

http://cdn.shopify.com/s/files/1/0166/4148/products/simplify_2_shirt_f7bg_460_large.jpg?2173

They brought this one back! thought all the Lotus fans would appreciate it.

[asshanson]

Some good progress this week. Fuel tank and all lines are re-installed, still need to verify this is an inline Walbro 255, but it sure looks like it to me. I couldn't get the foam off without ruining it so I just left it on.
http://www.mitsustyle.com/photopost/data/675/medium/fuel_pump.jpg

The new intercooler is great, OEM is tube and fin design with 14x6.5x3.5 dimensions, the new RLS intercooler is bar and plate design at 14x7x4.5 inches. So a little big bigger volume plus greater efficiency should net some gains, plus the heat shield will help to block some of the radiant heat from the engine below it:
http://www.dsmstyle.com/photopost/data/675/new_intercooler.jpg

Heat shield installed:
http://www.dsmstyle.com/photopost/data/675/heat_shield.jpg

To further reduce IATs I am adding ducts inside my side scoops and routing that air to the intercooler shroud. I bought some bumper ducts for brake cooling and just cut off the flat mounting point, and then a 10' section of 2.5" silicone hose. Total cost was $100, the RLS company that makes the intercooler offers a complete bolt on air duct kit for $900... so I went the DIY route.
http://www.dsmstyle.com/photopost/data/675/ducts.jpg

Test fitting the duct inside the side scoop area:
http://www.dsmstyle.com/photopost/data/675/scoop_test_fit.jpg

Marking the length of tube I need to cut for each side:
http://www.dsmstyle.com/photopost/data/675/tube_test_fit.jpg

Here is the modified roof scoop shroud with the side inlets. I used some 2.5" aluminum piping Brandon gave me (thanks again!), and then on the inside I expoxied some plastic pieces to direct the flow through the intercooler, to ensure it doesn't go back out the roof scoop or something. Then I painted it black and clearcoated it because it was quite ugly.
http://www.dsmstyle.com/photopost/data/675/shroud_1.jpg
http://www.dsmstyle.com/photopost/data/675/shroud_2.jpg

Finished product:
http://www.dsmstyle.com/photopost/data/675/engine_bay_complete.jpg
http://www.dsmstyle.com/photopost/data/675/intercooler_and_pipes.jpg

Based on real test data from companies that sell these kits, those side pipes will triple the airflow to the intercooler (which makes sense).

Also installed my header, exhaust, and Braille 2015 battery.

Things left to do: Retune, paint wheels, finish interior, and maybe some gauges. Most notably a fuel level gauge (car doesn't have one) and oil temp for the track.

[turbotalon1g]

Fuck that is sick.