Julian H

Reading Pier’s [Kal-El] Project Scope Creep in this months LF encouraged me to write a little something about my recent upgrade. My story started with exactly the same engine as Piers, the K series XPower 140, except I already had a suitable R500 exhaust with cat and R500 flywheel fitted by the previous owner. My first upgrade was a remap by Z&F Tuning as featured in LF which I was very impressed with over the standard ECU, a little more grunt through the midrange, much sharper throttle response, span up smoother and [optional] clicks and pops on overrun. My appetite whetted for much more got me researching for the future of my engine upgrades. Reading various sources on the internet and speaking to some local L7C members I managed to get a copy of Oilys old videos. I watched them with keen interest several times. My enthusiasm took over and I decided I could do the job myself so bought some [supersport] cams. Then realisation struck. I don't have a garage, I don't have the tools, I don't have the time and don't have the skill or knowledge to do the head modifications as well as necessary for best performance anyway. So I made contact with Dave and after a few flutters on spec decided on one of his kits, although learning I would need to have to have work done to the bottom end to ensure it was going to be strong enough was unexpected. I phoned Dave a couple of times in March and after much emailing too and fro on the finer details I asked for a date to be put in the diary. October was the response. To say I was gutted was an understatement. Like the best restaurants being the busiest, I reasoned I should wait, so I agreed the date and sat back in anticipation. In the meantime, Dave had suggested a wise move for me would be to get a 4-2-1 exhaust collector for my existing setup. Even though Caterham Cars website stated they were out of stock, I phoned them and was delighted to hear they had one. Despatched to me quicksmart, I removed my cat and fitted the collector in its place and straight away, more torque, just as Dave had predicted. So that little upgrade had to do me until October. After the long wait, my turn had come. Leaving home last Wednesday in the pouring rain at 5.00am for a 2 hour journey especially to avoid the worst of the M25 traffic, I ventured up to see Dave in Milton Keynes. After two days work, totally unflustered and with meticulous attention to detail I now had an engine that is as bombproof as it needs to be for me and a very nice uplift in power from before. I have balanced rods, forged pistons, motorsport bearings. Including the skilled headworkmanship, the top end is fitted with my SS cams, Piper vernier pulleys, Paul Iveys 29.5/26mm valves and Piper bits and pieces sufficient for the best hydraulic cams [bP285 or 300’s], including preparation for future fitment of a manual cambelt tensioner. A nice and unexpected touch was Dave removing the spare engine mount and fitting a perfectly shaped and finished cover plate to fill the void left. Top of new bottom end. Porting work example Head and plenum/TB in place Piper vernier pulleys Getting the timing spot on Filled with suitable oil for running in for the next 500ish miles, I went out for two runs with Dave checking everything top to bottom on my return each time, then he pronounced me good to go. I was torn, I so much wanted to drive my new mini-beast but had enjoyed my time with Dave, met some of his neighbours and a few of his friends, including a couple of other K series engined car nuts [Elise and Westfield], and of course his lovely wife who made me feel as if I were one of their family, that I also wanted to stay! During my time with Dave he identified my slightly OCD nature. He knew I couldn’t go home without getting my new set up as good as possible. He’d already discouraged me from getting the Emerald at present, saying it would only make a modest difference unless I went to the expense of a rolling road session which would be wasted if I do the rest of my upgrades sooner rather than later. Having the previously good experience with ZandF Tuning [now called Kmaps], on Thursday evening I dropped Mark Stacey an email in the vein hope that he could see me the following day [i had already found out he was only 50miles from Dave’s so had to be done]. He had a couple of other appointments but could fit me in if I could be there at midday. I was a few minutes late but after introductions and brief conversation Mark set to work with his computer, plugging it into my car and noting a few readings. Dave had suggested a new rev limit [of 7,800], changing fueling to suit the cams [which Mark had in his map already] and fine tuning the idle. Mark went into his office to do some work on the map on his laptop, loaded them onto my ECU and sent me off for a test drive whilst he tinkered with another customers MGTF. Wow, my engine had been transformed, Dave’s hard work had been released, a huge improvement. The only negative was the idle speed. 1,250 was too fast, so Mark dropped it to 1,100. I liked the hunting nature of the new cams at idle [with verniers] anyway so didn't want to dial it all out. I am really impressed with what Mark had done with my ECU after an hours work. At my request he also retained the operation of the standard Rover immobiliser and the clicks and pops from the exhaust that I so loved from the previous re-map. I understand Mark is now offering loaner ECUs out too, so Supersported K series owners can even try one before they buy. So, for now, I am running in my new engine, I so desperately want to rev it all the way because it really wants to go, it spins so sweetly that boring cruising along the motorway is much more tolerable than before but plant the throttle and you hear a much more purposeful exhaust note, cams buzzing away and the car flying off with gusto... What does the future hold? TB’s and a new ECU first which I suspect I am going to do myself and the final cams which I won’t. Having read the Dynoplot website, I hope that will give me around 205bhp/149lb/ft with Piper BP285’s and in Daves words, the BP300’s should offer a little more. Maybe I’ll get to 210bhp, who knows, but for now, my strangled engine [on VVC plenum and 52mm throttle body] will have to do! Roll on some induction roar!

I must say you do have rather more than your fair share of roundabouts. A little too busy to play properly I am afraid.

Hi Twas me, on my was to see Oily. On my way home tomoz so keep an eye out!

I hope to change back to CR500's from ZZS, does that count? Oily removed my boat anchor front engine mount today and in his typical style fitted a beautifully made cover plate to fill the void left in the cambelt cover. Edit- the mount weighs in at 995g with the four bolts and the cover and rivets to replace it probably only weighed around 50g so saving nearly another kilo... All the aloominum removed from the inside of my cylinder head must have saved some weight too

If you are buying a hood take a look at the "latest" Soft Bits 1/2 hood first

Is it not possible to buy the plug and fit it directly to the loom in place of the original? More work but would be a neater solution?

Hi Thanks for the information. You have given me the impetus to do the job. Interesting that the holes lined up. What are the odds of that happening? I'll probably start by looking at the passenger seat and see how I get on but the weight saving is superb for the price!

Hi Lawrence. You have a PM. Tell me more about your tillet installation. Did you need to drill new holes?

Mankee, thanks for the info on the pulley. I wonder what it was suitable for if it does not work with dry sump and is not suited due to lack of rubber insert? Is an Elise K series different I wonder. Graham, it seems like you have been on this crusade before. The new light blocks are still horrid rubber. CF ones are no longer available from the former 3rd party sources

Hi I found the archive... If it's not too greedy I'd like these please Ian 2011 Feb, Apr, Mar, Aug, Nov 2012 Jan, Mar, Sept, Oct 2013 Jan, Apr, July, Nov Thanks

Hi Ian I might like a few Low Flyings please. Is there a list of the content of back issues anywhere?

Good to see you out and hope to see you at a mid-Sussex meet sometime! Cheers

Hi Ian TTV might still have some if I phone. Do you know if they would fit? J

The ebay ad only refers to Lotus Elise and Exige. Will one fit a Caterham? [possibly a numpty question..?]

Reading the Avon description of the ZT5 it does not appear to be anything like the equivalent of the XV3!

Looking super clean, two up. I followed you from Forest Row to Wych Cross in my white Polo at around 6pm!

Hi A few of us are going to see Michael Palin next Saturday at the Congress, Eastbourne. Two have had to pull out so fellow member has 2 spare £31.50 tickets. Its also the carnival and fireworks so make a day of it BM me and I'll put you in touch. Cheers. Julian,

The cat is more likely to be either in the engine bay (EU legislation (?)) or built into the silencer (as a Powerspeed). I agree it looks much nicer!

Stick with CR500's if you can

I can't imagine it would be too difficult to drill, especially if you have a removable boss to use for hole setting out and another wheel to give you a good starting point. A metalwork company should be able to drill for you if you aren't confident. As Paul says, measure twice, drill once !

Hi I understand, as of only this morning from a learned L7C member, that the wheel does need drilling. He had a local company do it for him to make sure it was right. Getting the holes exactly right is not to be sniffed at?

You lucky man. I have a few more weeks to wait until I go!

Wow, so much information to take in! I am pretty comfortable taking Oily's advice, and have done so all the way through my decision making process, despite my wobbles on insecurity. I am not sure what cams I will go for but I know I won't be going the solid route so Daves K13 head will do me just fine. Dave I will be in touch shortly. Thanks, Julian

Torch for when you come away from a club meeting in the evening.

Hello Dave As you may imagine, my head has been in a spin regarding my choices. If I can see between 200 and 210BHP (and a nice torquey response?) with the BP300H with the head as it is that I think I would be best served taking your advice. My reservation is that I have read many posts where the experienced advocate the 1444's (and the lower BP285H) but little on the BP300H? Julian