Lotus Elan

Cosworth YB Turbo Into Elan

PostPost by: stevebroad » Thu Nov 30, 2017 12:49 am

In order to eliminate turbo lag I am designing a nitrous system, combining Wizards of NOS (WON) and Nitrous Oxide Systems' (NOS) philosophies, methods and components to suit my needs.

I have a NOS kit, bought way back in 2004 but never used. However, the kit is a wet system and I am going dry so the nozzles are not usable. NOS do a suitable nozzle for direct port injection but they would cost around $100 for 4 delivered. So I decided to make my own. The kit has the jets I need along with pipe, olives, nozzle caps etc. However, the solenoids are 14 years old technology and WON have a much better progressive unit called a Pulsoid, so I will get one of these.

Fuel will be provided by my existing 8 injectors so no need for another solenoid or extra nozzles for fuel.

NOS nozzle:
nos-jet-1.jpg and


My effort:
nitrous-nozzlemade-291117-1.jpg and


nitrous-nozzlemade-291117-2.jpg and


Took me around 30 minutes to make. The other three should take less than an hour now that I have worked out how to make them. The gas exit slot will be cut once the nozzles are installed and I can cut them so they face the valves.
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PostPost by: stevebroad » Sun Dec 17, 2017 6:36 pm

A little more progress.

Made a nitrous distribution manifold.

20171212_115843.jpg and


20171212_152102.jpg and


The engine loom has been completed, just need the chassis and dash looms which should be completed before Christmas so the car should be able to go back for installation early in the new year.

engine-wiring-loom-141217.jpg and
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PostPost by: stevebroad » Thu Dec 21, 2017 4:46 pm

New TIG welder arrived today (the pair in the background have stopped working). I can now get back to welding on brackets that will hold the exhaust shield on, once I work out what all the extra dials do :-) This one can also stick weld which may come in handy.

20171221_163139.jpg and
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PostPost by: vxah » Thu Dec 21, 2017 5:24 pm

Why the dry system? I thought the best way was to inject as a liquid so that as it turns to a gas it absorbs the heat from the boosted intake air? Where is your heat going to come from to keep it gaseous?
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PostPost by: stevebroad » Thu Dec 21, 2017 7:14 pm

vxah wrote:Why the dry system? I thought the best way was to inject as a liquid so that as it turns to a gas it absorbs the heat from the boosted intake air? Where is your heat going to come from to keep it gaseous?


Dry system because existing 8 injectors are more than capable of supplying the extra fuel, no point in complicating matters.

Liquid will be injected, instantly turning to gas once out of the nozzle. What do you mean by your last question (Where is your heat going to come from to keep it gaseous?) ?
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PostPost by: vxah » Fri Dec 22, 2017 8:10 am

Sorry, I think I misunderstood what you meant by dry system. I thought you wanted to inject the N2O as a gas rather than a liquid, that would mean it has to turn from a liquid to a gaseous state somewhere and heat would be absorbed in doing so? The sort of thing that can freeze control solenoids open :shock:
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PostPost by: stevebroad » Fri Dec 22, 2017 5:54 pm

vxah wrote:Sorry, I think I misunderstood what you meant by dry system. I thought you wanted to inject the N2O as a gas rather than a liquid, that would mean it has to turn from a liquid to a gaseous state somewhere and heat would be absorbed in doing so? The sort of thing that can freeze control solenoids open :shock:


Yeah, that wouldn't be good :-)
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PostPost by: Spyder fan » Fri Dec 22, 2017 6:43 pm

Steve,
Did you really start this project in 2004? I just went back to your 1st post in the thread.

Thanks for all the posts and inspiration.

Merry Christmas and happy new year
Kindest regards

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PostPost by: Chancer » Fri Dec 22, 2017 7:17 pm

And from the 1st page I read that Steve broke the car in a street championship in 1984, it may not have turned a wheel in the intervening years making this truly the project of a lifetime!!

Keep up the good work Steve.
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PostPost by: stevebroad » Fri Dec 22, 2017 7:19 pm

Spyder fan wrote:Steve,
Did you really start this project in 2004? I just went back to your 1st post in the thread.

Thanks for all the posts and inspiration.

Merry Christmas and happy new year


Well, actually started this project in 1974 when I bought the car for ?550. It stayed standard for a few months before I built the first of many engines for it, culminating with 168bhp at the wheels in 1985 which ran 12.92 at the Pod.

23.jpg and


I fitted an early nitrous system in 1978/9, but it never worked properly and the 12.92 was without gas. This was a wet system, ie both nitrous and fuel were added via solenoids and jets as the engine was running 45 DHLAs. The YB now fitted can supply the extra fuel via the injectors so I am fitting a dry system.

img050.jpg and


65.jpg and


I then broke it at the 1985 Street Racer Championships (where I was favourite to take the under 8 cylinder crown :-( )

163.jpg and


167.jpg and


Shortly after that my daughter was born and family life seemed to get in the way and the car was left languishing in a tatty shed.

elan-in-shed.jpg and


In 2004 I got my mojo back and dragged the car out of the shed. The original plan was a complete chassis up rebuild using the existing engine but standard shopping cars now had more power! Fuel injection may have produced 20 odd bhp (if lucky) so I made the fateful decision to go the turbo route.

There have been numerous times when work has stalled for many months, mainly due to loss of interest. However, for the last couple of years I have worked on it on a regular basis, albeit often redoing things that I have changed my mind on :-) For example, weight reduction wasn't on my mind originally, but now it is an obsession :-) Also, going to inboard rear dampers wasn't in the original plan but was now required in order to be able to fit the width of tyre I wanted.

rear-ns-supension-bing-assembled-171114.jpg and


Getting close now, which is somewhat scary, is it going to work or be a complete disaster? Who knows?

Merry Christmas to you also and a great new year.

Steve
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PostPost by: Certified Lotus » Fri Dec 22, 2017 11:57 pm

Great perspective of where you started and where you are today. Wishing you all the best Steve, I continue to be in awe of the work your doing on building this car. Merry Christmas.
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PostPost by: The Veg » Sat Dec 23, 2017 5:04 pm

Wot Glen sed! Watching this project has been great fun and I'm looking forward to seeing how well it works.
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PostPost by: stevebroad » Sun Dec 24, 2017 10:43 am

Thanks guys. It has been a long and fractured journey, but the destination is finally in sight.
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PostPost by: Bud English » Mon Dec 25, 2017 4:47 pm

Keep up the great work, Steve. Can't wait to see what the new year brings! :D
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PostPost by: stevebroad » Thu Dec 28, 2017 11:13 am

Belated Christmas present to self arrived from China today :-)

I can finish the nitrous nozzles now.

20171228_110012.jpg and
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