SIDC track day - Knockhill - 29/4

Awesome day.. SIDC at Knockhill - big tks to John Stewart for another great day

Esprit was running nice: depsite my still getting used to it and running ill suited A032s which went off way to quickly.. her pace compared to what I was used in the old M was quite mind-blowing... I think in the right hands she'd easily put in sub-60 [at Knockhill] as she wasn't half as difficult as I expected but getting more than 80% will take more skill than I have through the back complex..

The Extreme Evo was very quick and prb that fastest single lap on the day depending on what Ross or the 340R put in - It past me on the pit straight after I was slow going round a 7 and he took advantage of my pause... hard to stick with him tho as he carried a lot of pace through the back complex .. went over to speak with them and their best lap of the day was a 58 secs.. and I expect the 340R and superlights were running a bit quicker but for a big ol gal she was running nice straightline until her intake temps started to run hot.. (will sort that b4 silverstone) great fun to chase down Elises/Scoobs for a change. Looking fwd to having some tustles with those Type R Exiges next..

Was a pleasure to be chaffeured in Col's Golf - loved that - such a sleeper but with honest pace..and benign handling - Esprit struggled for traction out of the slower bends without a slipper and no slicks but it was all good nonetheless... good fun to steer.. quite old school - lots of degrees of counter steering but I learned more in that day about oversteer than I have since owning the M.. I suspect she'll run nicely on the wider tracks as she's pretty long-geared and in going into 5th she was still pulling like she was in third..

Yoshi's Lex getting ever faster and is pretty sweet out of Taylor's now - just needs bigger or faster spooling tubbies.. those bollards stopping him with his BTCC launches over the kerbs.. hope the whine isn't anything too major..

Great to catch with SSC guys and tks to Callum, Dave etc etc who came over to help me load up. Also nice to meet Shug and Gordon - gr8 to put names to faces and a pity I never got a chance to speak with more of the SE guys.

I stayed back with Dave B to watch some qualy - some cracking machinery out there and also AndrewW was running nicely in his #87 Fezza.

will post up my footage shortly
Top quality !!

Update - checklist before SIDC

Time starting to get pretty tight

Rear hatch should hopefully arrive tomorrow - need to measure up and fit

Dunc will be here by 6pm tomorrow to fit pipework, new BOV etc

Spoke to Kev (www.falkland.co.uk) and thankfuly he assured me Dash 31 actuator set to correct mechanical boost setting. This proves the G H-C chip is for higher boost applications - 1.4-1.6 bar me be supported given the 3 bar sensor.

Front bumper mods

Finished the front splitters and canards for the front bumper assembly... will post pics this week

Now looking to have a lower front bib - as per Sport 300 but as deep as the GT2.

See here: http://www.lotusespritworld.co.uk/EModifications/300Frontblip.html">

Sunday -

Rear exhaust can now wrapped - it took 50' (just) of cooltec. Exhaust to Turbo bolts tightened to reduce play.

Pilot holes for spoiler now drilled

Front splitters now on the front bumper - I'm reasonably happy with them although the extra drag may not be justified by their shallow angle of attack. However they are well placed to feed air into the brake ducts and side intakes. May try to get some side canards mounted before SIDC (Knockhill) on the 29th.

Dermot Ohare also says I need to try and adjust the throttle tps reading to as close to 100% as possible to gain the full map. Currently sits at 94%.

Will need to remove driver seat to get better access to footwell throttle cable.

Just waiting for the rear hatch now. msg left for Paul at www.plastics4performance.co.uk

Progress - some pics...

Dunc dropped over to set the throttle.

We now have 94% throttle on Freescan (compared to 71%) which should prove a lot better - new throttle cable planned (pref before S'stone).

Built up wing and checked for size - will need to drop in some threaded rivets to secure but should sit well. Plan will be to have longer legs machined for better rear visibility (if I can see anything through the polycarb deck that is..)

Turbosmart BOV not yet fitted as Dunc had the wrong diameter samco hosing - will drop by in the week to finish.

Bonnet pins now in position ready for new rear hacth - I can play with the heights for best fit and have some rubber washers and hose to reduce vibration.

Fuel pressure gauge fitted - will check once running - we canthen richen the mix slightly if the car continues to run a bit leann.

New wing arrived..

The new Cosmo Racing wing arrived from Canada - looks the business and packaging was excellent - price was fantastic - right now ally wings are really being overlooked in favour of carbon ones of so-so quality... Sport300 wing already removed ready..

Will fit Saturday - hopefully new rear hatch on its way next week aso I'll drill and mount my bonnet pins in lieu. Dunc popping down with BOV, plugs and leads.

Still no news on the front rubber lower air dam but hopefully will have arranged over next couple of months.

Need to buy some heavy duty rubber hosing for bonnet pins and some L-brackets for canards etc.

will post pics once fitted

Sunday - work underway..

So basic update today:

Dunc never managed to get down today but hopefully he'll be across this week to help fit the new BOV.. so I fired on..

New O2 sensor on. Last one was def not a proper Delco unit.
Wrapped O2 with cooltec as it runs pretty close to the tubby
Rear deck spoiler off - new ally wing on its way from Canada
Rear hatch off - ready for new one
Exhaust shield off ready for wrap.
New IAC to go on at some point.
Switched MAP sensor for a spare
Ran Freescan for errors codes and data load.
Re-set idle and fuel maps.
Car runs lean 13.5-13.9) and slightly lean once warmed up (13-13.2).

Tried switching spare idle control sensor but reverted back to the static off one previous owner was using, which is basically glued the spring into a fixed position.

fpr disconnected, BOV disconnetced, loom holders disconnected and plenum cover removed and ancillaries disconnected. The 2 secondary injectors sit inside the connector between the chargecooler and the plenum but have their own inlets into the plenum. The injector tips are coated in red gear oil - not sure if that's standard but I know the fine lube qualities of gear oil (i.e. 3-in-1) was a must for carbs etc so suspect the same is true for injection units.

Silicon removed for mating surfaces ready for new gaskets. What's cool is that previous owner has ported all of the inside of the plenum, turbo intake, throttle inlets etc.

B'flies look in good order and move well on cable. No massive play but will have someone try the pedal and watch the b'flies for full apparture.

Looks as if the lower splitter can be unbolted - def looks like I can build some sort of proper lower diffuser set up and use a couple of quick release wing nuts like the front bumper. Once removed it will make it easier to unload/load the car from the trailer.

Sunday - O2 and throttle... BOV?

Hopefully Dunc coming across today with new Turbosmart BOV.. One that isn't so tired as the Forge replica one. I could have gone for a new spring but thought I might as well replace.. it's only money.

Aiming to set throttle cable and fit new O2 - unfortunately connector not long enough so will have to drop by a factors next week to pick up a 4-pin connector.. I could bodge a re-wire but figure wiring dodgey enough - new loom poss' for next year me thinks.. :roll:

With the Freescan hooked up I'm hoping I can adjust at the pedal box with good throttle travel instead of having to unbolt plenum and ancillaries to get into the fine throttle adjuster... will see how much slack there is. There's also a few stops on the pedal to play with. :idea:

Above is a pic of a Turbosmart BOV

Data, charts and Freescan.... insomnia cure..

Ok - I've started to break down the data files form Freescan. As I work with data and charts all day at work then I find this straightforward enough to do. It's just another number of variables to analyse - trick is to know the significance of values and this is where the Freescan manual is invaluable. For most this is a quick road to sleepyville.. I acually quite enjoy it and may write a quick macro once I know what data I will always pull from a csv file and what format I'd want it in. Charta are so much easier to comprehend than mindless tables of data upon data... zzzzz

Rechecked and sorted my figures and removed nil values such as off throttle position readings or idle values - end result is that TPS shows good readings and a linear movement between TPS-Volt and TPS position. I will run a steadier run @ weekend by gradually increasing and decreasing throttle/revs to double check. Pretty sure TPS is fine.

However the O2 (Lambda) readings are a bit strange - also they show a very lean reading at idle (<0.03-0.3) and off throttle yet rich to very rich reading (>0.3-0.9) on throttle - this may be due to the O2 sensor and I'm replacing that shortly from SJ Sportcars. Knock reading appears to be ramping up continually at idle with a few occasional knock retard recorded at max revs at idle (not recommended..). Will check Knock at next outing where engine loads are more realistic and there's positive airflow, full throttle etc.

Air-fuel shows 13 (measures 12.9 on wide band lambda) under load and 13.5 at idle or off throttle.. a bit lean..

Iffy idle is due to absence of an IAC and set idle to 1200 rpm. Not sure if this is playing havoc with the O2 at idle or not. Hole is blanked off and sealed with small pipe extruding.

MAP readings look good and rise steadily in line with revs with no obvious drop off. However thes ereadoings are not so relevant until car is on the move. At least they don't indicate a vacuum leak.. yet.

However spark advance does looks off and dips significantly between 2500-3000 revs where there is also a flat spot in the O2 reading. There are notes to run plugs one stage colder than std and may give that a go.

Update on sensors - money money.. (6/4/06)

Ok .. bliming sensors
- new plenum gaskets ordered - check
- new O2 sensor ordered - check
- new Turbosmart BOV on way - check

Once these are fitted and throttle adjusted to 100% then we should be getting somewhere - I wonder if the actuator has to be re-set to the mechanical minimum - i.e. 0.65 bar..?

Spoke to Steve - car doesn't run an IAC but is blocked instead with a small pipe to allow some air past the throttles. It idles lumpily but seems to work. He reckons TPS should be fine even if not 100%.

Sent Dunc the Freescan + manual - we can use Freescan to check we have full throttle and a good mix. He's also going to use an LM-1 to double check the lambda. Dunc will hopefully get across the weekend before SIDC to fit the BOV and adjust throttle.. may try to get dad to come across and help me adjust throttle and fit O2 before that, so it's done.

Then I can focus on fuel mix, charge temps and boost.. IF the wiring holds together!!

slow progress..

Freescan - first scan results - not great news..

Dermot checked the various data files I sent from the first Freescan run. He found:

Baro and Map sensors do not read the same when ignition is on and engine if off.

At idle the Map is 0.19-0.2 at 1100 rpm, normally this is about 0.40-0.5. (2 or 3 Bar ?)

Lambda sensor is not working, no 0-1V swings at idle once sensor is warmed up. IAC valve is not working, should park at 170 and drop to acheive steady idle (40-70).

TPS sensor certainly does not go to 100% He was also not happy with the voltage output from the sensor, it is not linear and reproduceable in places

Dermot's recommendations:

New O2 sensor or check connections, get a Lotus one
Clean and possibly replace IAC valve
TPS sensor may also need changing, once throttle cable is set right
Check ecu again for any error codes

He expects engine should be running very poorly, fuelling should be terrible as it will be running off tables. Will check the throttle adjustment and check or replace all the sensors. Will then record the map settings again at the car's next outing.

[urgh]

F40-style rear hatch almost ready

The clear F40-style Flexiglas(c) rear hatch is almost ready. Paul @ Plastics4Performance www.plastics4performance.co.uk has been slowly heating and cutting the vents into the one peice panel - a first for the firm. The F40 rear deck used special tooling and was sealed to the rear clamshell.

The new deck will allow better cooling, reduced weight and also more space to fit the eventual ram air system (65mm ram pipes, carbon airbox and ram air cone filter).

The hatch will use quick release bonnet pins for quick access. The total weight of the entire rear hatch will be circa 5 kilos - a big weight saving over the std (albeit) lightened deck, which is approx 10-12 kilos.

A perspex copy will be used for initial fitting and locating of the 8 pics that will be used. It will also serve as a temporary back-up should anything happen to the Flexiglas one.,

Front canards and splitters cut - just need some small brackets and I'm good to go. Drilling multiple holes in the front bumper will allow me to adjust and I can later use the same holes to try different designs.

The search for a usable rear wing continues. I will look again at the rear Sport300 spoiler tomorrow to see if I can build up carbon - but that will always be a compromise; but finances may dictate for time being.

Next shakedown is the SIDC event at Knockhill - 29th April.. usually wet, doubly hard as EF and now Esprit has twice the power.. nervous, me.. nah.. umm.. err....

Freescan update - making progress

Quick update: Freescan hooked up and running A1.

7 csv files downloaded - marked off figures against manual. So far ony pre-start, cold start to idle then warm idle to full temp plus full throttle at idle.

Will send the maps to D and see what he thinks - fact the throttle position was showing at only 77% instead of 100% is worth checking out..ahh the novelty of being able to start the car without a jump or a push..

right - I'm off to have some tea then cut some carbon canards..

Jon