Weight Reduction: Best Bang for the Buck

A&Q about Lotus

Q:
Added the K20A to the first post.

Andrikos -- be aware that Lotus uses different batteries. Mine came with a ~28lb Exide and I saved 16.5lbs with the Braille including all the mountings. The weight savings in the original list uses the modified battery's specified weight minus the Lotus battery weight listed on Sector111's site (24.2lbs). If you use different savings found by different people, they aren't going to be comparable. Different batteries, different mounting choices, etc.
A:
Originally Posted by Andrikos I put an odyssey PC625 in my car (thanks Greg for the free battery! JK ) and the weight savings were 13 lbs.
The stock battery is 30.4lbs and the PC625 is 17.4lbs.
I'll update my spreadsheet and post it.
I also saved some weight (Oz) by not using the Lotus fastener and by making an aluminum clamp to keep the battery in place. This puppy is going nowhere!
The Odyssey battery was 13.4 lbs, not 17.4!

We saved 17 lbs even (according to your scale ) with that installation. When my car is ready we'll weigh the difference to the gram on my postal scale (including our bracketry).
A:
Originally Posted by Bane The Odyssey battery was 13.4 lbs, not 17.4!

We saved 17 lbs even (according to your scale ) with that installation. When my car is ready we'll weigh the difference to the gram on my postal scale (including our bracketry).
oops!

Expect a long winded e-mail from me shortly.
A:
Originally Posted by Taxcheat Added the K20A to the first post.

Andrikos -- be aware that Lotus uses different batteries. Mine came with a ~28lb Exide and I saved 16.5lbs with the Braille including all the mountings. The weight savings in the original list uses the modified battery's specified weight minus the Lotus battery weight listed on Sector111's site (24.2lbs). If you use different savings found by different people, they aren't going to be comparable. Different batteries, different mounting choices, etc.
Got it.
24.2 - 13.4 = 10.8
A:
Masheen,
The 2ZZ in my Elise made 180 HP measured at the drive hubs on the Dynapack chassis dyno we always use for ECU tuning. This is about 15 HP higher than what we've seen from other Elise's on the same dyno, and probably has more to do with the way I broke the engine in when it was new than anything else. The K20A engine that replaced the 2ZZ made 240 HP on that same dyno, hence the 60 HP increase. As for torque, I said 60 lb ft more mid-range torque, not peak torque. My 2ZZ made peak torque at 6,923 rpm and recorded 128.2 lb ft at that point, but peak numbers don't tell the story accurately from a driveability standpoint. The 2ZZ's torque curve drops below 120 lb ft at 4,300 rpm, falling to a minimun of just 107 lb ft between 5,400 and 6,000 rpm, then once the lobe switch happens it comes back up past 120 lb ft at 6,500 and falls back to that figure by 7,850. The K20A makes peak torque at 5,239 rpm, recording a maximum of 172 lb ft at that point. It also holds at 170 lb ft up to 6,500 rpm, so right where the 2ZZ is extremely weak the K20A is extremely strong [170-107= 63 lb ft] What's important here is that the K20A makes more torque at just 2,500 rpm than the Toyota makes anywhere in the rev range, and the curve doesn't start tapering off until 6,500 so the HP keeps climbing all the way to the 8,500 rpm redline.
This K20A is rated by Honda at 220 HP [at the crankshaft], but that rating includes their whisper quiet intake system, emissions biased exhaust system, and extremely conservative ECU mapping. With my velocity stack intake, optimized in length to produce the best torque curve, my headers, which are also designed to maximize mid-range torque, and Hondata K-Pro ECU tuning which is still rather conservative but nowhere near as much so as Honda's we're able to increase the output of the stock engine by about 45 HP. We've dyno tested quite a few of these engines in stock Honda trim, and they generally make 193-197 HP on the same dyno my engines were tested on.
It's the torque curve that's the most important thing, so that's what we tune for. The HP curve is simply a function of torque and RPM, so a sweet torque curve always give you good HP.
Joe
A:
Hi TaxCheat,

The XLS file you sent is still not parsed, did you create it that way?

Jeff
A:
Originally Posted by ZakSkiGuy The XLS file you sent is still not parsed, did you create it that way?
Andrikos is the XLS guru, not me. I re-uploaded my latest copy which has more items and a currency/weight conversion for UK owners in case that helps. Otherwise, I have no idea what not parsed means.
A:
Originally Posted by Joe McCarthy Andrikos,
This will more than likely start the same feces-slinging game from that group of the usual suspects we all know so well by now. Their Radar seems to be slipping up a bit lately, but I'm pretty sure they'll chime in sooner or later with the same old lies. It's been going on for several years now, very soon after I first introduced the K20A Elise conversion to Europe and was immediately ripped off and denegrated publicly at the hands of those who stood to make a substantial profit from said thievery and their cohorts.
It all started when a used K20A, dyno tested only in England, didn't make the same HP as the engine in my Exige. The idiotic assumption being that since that one didn't make the same HP as mine that I must be a lying, and that any data from the Dynapack chassis dyno we routinely use for ECU tuning must therefore be pure and utter B.S. It degraded rapidly into something akin to being attacked by a pack of mad dogs, something I tired of pretty quickly.
Through a curious quirk of Human nature [commonly known as the Coliseum Effect]a group of seemingly sane individuals joined in on this gang-bang and have added their malignant ponderings to the proceedings. Mostly I simply ignore them. I'm well aware that I can't change the opinions of those people with closed minds, so I figure why waste my time trying. I have better things to do with what few years I have left.
-Snip-

A:
Originally Posted by masheen you say:

190 + 60 = 250 hp
134 + 60 = 194 lb.ft

i find:



where does the difference come from?

The difference mainly comes from using the Church Automotive dyno packs - its been proven, and admitted, that they fettled with the power supply and the dynapacks over read. Just one of those comercial facts of life I suppose but forwarned is forearmed.

Basically his claim of 240 thundering horses actually means about 200-205bhp back in the real world. Perfectly Ok but hardly exciting.
A:
Originally Posted by Taxcheat Nice! I didn't think of doing it as a graphic so didn't know how to handle the "touring wheels." I took me a while to get to it...


Originally Posted by Andrikos lol, here comes Tim! Why didn't you just thwack him for me...
A:
Imagine the weight savings if you filled up the tyres with helium instead of air?

Mike
A:
This thread just about gave me a heart attack!!! I was looking at the nice list of lightweight goodies and yesterday I ordered a set of the Craftsquare CF Side Mirrors from Sector 111...I noticed they were listed as $1,050 for a set of rearview mirrors and were down at the bottom of the list. I paid $525 and started to wonder if I was only getting ONE MIRROR!

I had to call Sector 111 to verify I was getting a set! Maybe someone will move these SET of rearview mirrors up the list and revise to the correct $525.
A:
My scale showed the late 05 sealed battery to be 26.5 pounds with terminals. Including the batt cover probably gets it over 28 pounds.
A:
Originally Posted by mchristian ... Maybe someone will move these SET of rearview mirrors up the list and revise to the correct $525.
Oops. Fixed in the first post.
A:
FYI: The hardtop header trim panel weighs 2.18 lbs. (Just weighed it at work)

I'm probably going to get some speaker felt and glue it over the area on the hardtop where this this mounts. It's a PITA anyways to push/align the center bolt all the time
A:
FYI #2: The Fidanza aluminum flywheel weighs exactly 7.865 lbs., saving 5.515 lbs. (stocker is 13.380 lbs.)
A:
Originally Posted by Taxcheat Lots of updates to the table on page 1 (found the quicksilver -- Ragnorak lists it on their site, added a few links to threads with more info, etc)

Among SELOC's favorite weight reduction items seem to be hubs and the fuel tank. Not sure if either exists for non-Rover Elises, but worth a bit of searching.
Fuel tank....(says S2 version coming soon).



Hubs....are already avilable.





Very nice stuff.
A:
The passenger footrest is 1.1 lbs. It is held with velcro.
A:
The stock dash top piece is exactly 6.230 lbs. I just weighed it.

I had a couple air bubbles in mine - and my dealer installed a brand new one yesterday. I kept the old one.

I posted it here so it's searchable...

Now if I can just learn how to do carbon fiber at home
A:
I just got this an hour ago when I got home:


(6" 2bular exhaust with stubby flush tips, FF street header with test pipe)

FYI: I weighted the new ACT XTSS clutch yesterday:
2.510 lbs. for the disc
8.285 lbs. for the pressure plate
Total of 10.795 lbs.

I have to post all the weights here so they'll be searchable.

I'll weigh the exhaust tomorrow.
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