Archive for the ‘ Bodywork ’ Category

Front diffuser

Well we’re back on the Project N2 build, finally with a goal not to stop until she’s finished! Sorry to our followers, but its been a busy summer and we haven’t had much time to make progress on the build.

As an opener to the new ‘build season’, what better than to show the most recent progress made on the front of the car!

The design of the mounting points of the front diffuser has been re-visited and re-designed. Instead of bolting straight through the diffuser, we opted to bond on some aluminum panels in an effort to distribute the load of the support straps over a wider surface area. It also allows for a larger mounting surface for other future accessories, and a more sturdy surface for the thread rivets to bite into.
The straps have been custom made to be adjustable in an effort to enable us to trim the splitter for the best possible aerodynamic ground effect.

We hope you enjoy the pictures, and stay tuned… MORE TO FOLLOW!







Carbon Engine Hatch

Courtesy of Mr. Dale Edmonds; our new carbon fiber engine bay hatch has just arrived.
The hatch has been moulded without any of the mesh vents that a standard Exige comes with; to induce superior air flow over the top of the car.

Foam core has been integrated into the part to increase the strength and rigidity.

What does everyone think?






Rear clam mounted

The rear clam is on the car!!!

Finally dove in head first into getting the rear clam on the car. In order to keep clear of any exhaust manifolds spoiler mounts, oil coolers etc. it was deemed necessary to keep the body mounts up high and out of the way.

Using some t45 tubing, body mounts were TIG welded in place; intertwining the rear roll cage and mounting points. They’re nice and stiff so they can be used to mount other brackets such as spoiler mounts etc.







Roof mounted

As promised, more updates!
So the roof is in place, the safety devices cage had 3 small tubes welded onto the front roof cross member that acted as good mounting points. I welded 2 more points into the left and right roof tubes for the rear fasteners.
The bolt points have been bonded to the roof; one in every corner and another in the center to secure the inner roof scoop skin.

Further reinforcement may be needed however it seems as though the compound used to bond the fasteners to the roof is quite strong.

The roof is a carbon fiber copy of an S2 exige roof with the extended roof scoop. The roof uses foam core in either side as reinforcement along with a Carbon inner ski to seal the air duct. It weights approximately 3.5 KG’s.





Rear side scoops mounted

FINALLY BACK TO WORK! Sorry it’s taken so long to update but with vacations, North America trips, and other shop duties… There hasn’t been much time to blog!

So, the side pods have been mounted solidly into place. A series of aluminum riv-nuts have been drilled and fastened into various chassis/ body panels to secure down the side scoops. The inner arches have been fastened down with 1.5mm thick aluminum panels which also double as stone guards for the rear air jacks.

Notice the side scoops are quite prominent compared to the original scoops… Back around January time, we sculpted larger scoops and moulded them in carbon fiber. This was all done to increase air flow into the engine bay for both the oil cooler and the engine air intake. The fact that they’re now roughly 25% lighter and way stronger doesn’t hurt either ;).

Stay posted for further updates… They’re right around the corner!!! 20120926-143445.jpg20120926-143455.jpg




Further bulk-head modifications

As one examines a certain Exige GT3 engine bay with the intent to plan the fluid passage-ways, one may find one’s self slightly stumped by the obnoxious and inconveniently located original Exige inner rear side panels. Said panels obstruct a vast amount of potential air flow from our modified GT3 side scoops; therefore making the location of the air intake, oil cooler, etc. quite obscure and inconvenient.
Yes it has been recognize that said panels do add some structural rigidity to the bulkhead and side pods, however after months if not YEARS of consideration, bickering, and heated argument…  THEY HAVE BEEN CUT OFF!!!

…..And then; the remaining sections where  reinforced by bonding carbon-Kevlar panels in place.

Now; we can plumb, duct, and mount to our hearts content!

Have a look at the pics and let us know what you think!!!

Firewall modification

As we’re now at the stage of fitting the rear clam, certain “standard lotus” body components seem to be affecting the clam alignment.

So instead of cutting EVEN MORE of our lovely carbon clam away, we opted to modify the rear firewall/ side sills so that the clam slid on nicely and also maintained a barrier between the cockpit and engine bay.


Teaser pics…

the body work is finally staring to come together; the panels are FINALLY almost lined up, trimmed, and fastened down.

All of that considered, and a much needed shop clean-up. I just couldn’t think of a better opportunity to take some pictures to show you guys!!!

And just for kicks… we mocked up some spare wheels and the rear wing for extra “flare”!!





Front clam side aero-catches

The mounts for the side aero catch pins have been fabricated and are now mounted in-place.

Therefore we can now deem the front clam…


Stay tuned for updates on the mounting of the rear clam and custom side pods!!!




Carbon Fiber Rear Clam!!!

Seeing as we have a weight target of 780KG’s for the entire car, we decided to replace our glass fiber rear clam with a Carbon rear clam to keep the weight down.

We where able to track down a genuine Carbon Exige GT3  rear clam and I must say… Not only is this puppy light, but it’s a work of art. All of the fibre orientations and core materials are configured to keep the clam as stiff and strong as possible.

And since we had a genuine Exige, glass fiber GT3, and CF GT3 rear clams all at the shop… Naturally the first thing we did was, WEIGH THEM!!!

Origional Exige>> 24.3KG

GF GT3>> 16KG

CF GT3>> 8KG

Enjoy the pics.