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Last 111, First Street Legal K20 Swap? (Part 1)

Last 111, First Street Legal K20 Swap? (Part 1)

Back in February of 2020, our longtime Lotus customer reached out about potentially building an Elise from the ground up. The idea was to build a car to his exact specs, a reimagined Lotus Elise. The plan was to buy a brand new tub chassis from Lotus and hand-pick, or fabricate, custom parts for one goal: his perfect “streetable” track day car. Most of the drivetrain and miscellaneous bits would be taken from his current 2011 Elise.

One-Two Finish at the 2020 NASA Pro Racing Season Finale

One-Two Finish at the 2020 NASA Pro Racing Season Finale

With the 25 Hours of Thunderhill postponed to 2021 (thanks, COVID) the final race weekend of the year took place at Buttonwillow in the form of a double header, Super Touring sprint racing and a 3 hour and 15 minute night endurance race as part of the Western Racing Endurance Racing Championships. We were able to use the month of September to properly prep both the Lotus Exige and the E36 BMW M3.

Two Race Weekends in August and First Win Of the Year

Two Race Weekends in August and First Win Of the Year

We went into the month of August feeling excited for two reasons. First, our K24 swap was finally complete on the Lotus and after a solid shakedown at Laguna Seca in late July by Graham and Tom -- it was finally ready for wheel-to-wheel action. Second, we would have 2 race weekends take place relatively close to each other, August 1st and 2nd at Thunderhill and then August 22nd and 23rd at Sonoma.

Trackspec's Exige S240 Project: Part 10, K24 Swap (3)

Trackspec's Exige S240 Project: Part 10, K24 Swap (3)

In part two of the K24 swap, we were left waiting for the header to arrive. We ordered a Hytech 4-2-1 header specifically made for this swap, which took a little over a month to get, but was well worth the wait! It fit perfectly. Other than trimming the J-pipe to length it needs no modification to fit any muffler designed for this chassis. Once fitted, all we had to do was make an extension harness for the wideband o2 sensor.

Second podium at the second race of the year

Second podium at the second race of the year

The first race of the 2020 season feels like a lifetime ago...and not because it was way back in February, but because the world as we know it has changed dramatically over the past 15 weeks. COVID-19 caused just about everything to shut down...businesses, offices, parks, restaurants, schools, and what can best be described as a “normal way of life.”

Trackspec's Exige S240 Project: Part 10, K24 Swap (2)

Trackspec's Exige S240 Project: Part 10, K24 Swap (2)

When we left off in part one of the K24 swap, we had the engine in the car and started getting things connected. Although it seemed like it was close to being done, there was quite a bit left to do. We decided to keep the factory dual oil coolers. This may change in the future, but we wanted to make sure the temps were stable even on extremely hot days. Moving along on the track is one thing, but following closely behind another car in “dirty air” and it can get hot pretty quickly. Because these cars are known to over cool engine oil, we installed a thermostatic sandwich plate with a 200F thermostat to help maintain proper temps.

Trackspec's Exige S240 Project: Part 10, K24 Swap (1)

Trackspec's Exige S240 Project: Part 10, K24 Swap (1)

If you grew up in the 90s and were into cars, then you’ve heard of the Honda B-series engine and how amazing it was. It was the “hot rod” engine of its time and my gateway into modifying cars. The planning, researching, parts sourcing, building, and then seeing how it improved the car’s performance is what got me hooked. In the early 2000’s, Honda came out with something even better..

Trackspec's Exige S240 Project Part 9, Brakes

Trackspec's Exige S240 Project Part 9, Brakes

In Part 8, we were waiting on a driver net before we could have the tech inspection done. The Schroth net with the new quick release mechanism that we originally ordered was still undergoing testing and its availability was severely delayed. So, we went with a equally good option- Safecraft.

Hard-charged our way onto the first podium of 2020

Hard-charged our way onto the first podium of 2020

We love the start of every race season because it represents new possibilities. In winter of 2019, we decided that 2020 is going to be a year where we’ll be more focused on endurance racing. While we love the NASA Super Touring (sprint racing) series, we realized we enjoy enduros even more. As a team, we are aiming to win (our class), podium, or at the very least finish the 25 Hours of Thunderhill with my E36 BMW M3, “Heidi.” So, that’s what we’ve set out to do.

Trackspec's Exige S240 Project Part 8, Roll Cage

Trackspec's Exige S240 Project Part 8, Roll Cage

With a year of rebuilding and developing the Exige behind us, we were excited to begin our “winter project,” the roll cage. When the car came back from the last track event of the year (a very wet Laguna day), we gave it a good wash inside and out before getting into it. We also had to do some homework and make sure that what we build is safe and legal for the the local sanctioning bodies we plan to race with. We followed NASA’s Club Codes and Regulations handbook as a guide.

Trackspec's Exige S240 Project: Part 7, Clutch, Trans, Misc.

Trackspec's Exige S240 Project: Part 7, Clutch, Trans, Misc.

At the last two-day track day at Buttonwillow with Speed Ventures, shifting in the Exige started to get notchy. It would sometimes be difficult to get into gear, but we kept driving it. By the last session of the day, we were not able to get the car into gear after pulling off into paddock. If the engine was off, it would go into all gears, so we suspected it to be a failed clutch that was not fully disengaging...

Trackspec's Exige S240 Project: Part 6, Fuel and Oil Control

Trackspec's Exige S240 Project: Part 6, Fuel and Oil Control

Fuel starvation is a well known problem with this platform. It’s mostly noticeable on long left hand corners because the fuel pick up is on the left side of the tank. It’s typically not an issue if I keep the fuel tank full, but every time our got down to about 70%, it would starve. This can cause a lean condition and be harmful to the engine, especially with forced induction.