Lotus Omega/Carlton rebuild

[adaptec]

I bought this car in Blackpool april 2006 and it has been sitting in my garage since then. The original engine and tranny was sold to finance the buy of the car. I've now doing some restoration and tuning to this car and hopefully it will be driveable next summer.

Basic engine spec:
3.0 24v block with oil spray cooling, bored to 96mm, decked.
Lotus crankshaft stroked to 89mm using Nissan SR20 rod journal
Forged connecting rods
Forged Wiseco pistons, 96,00mm (total volume with 89mm stroke 3865cc)
Total Seal piston rings
Mechanical camshafts with custom profile, reprofiled in Norway by KM Cams
Dual valve springs with aluminum retainers from dbilas dynamic
Ferrea stainless steel exhaust valves, 32,5mm
Bronze valve guides
SCE Copper head gasket with built-in titanium rings around cylinders
ARP head stud kit
Reinforced head with custom welding (trying to prevent heating problem)
Garrett GT45R turbo with Tial SS turbine housing with V-band, Tial 60mm WG
MagnaFuel fuelpump, Aeromotive FPR and filter, ATL fuel cell tank, 1260cc fuel injectors
Electromotive Tec3r engine managment system
Stiffer engine bushes

Drivetrain spec:
Tremec T-56 6-speed transmisson
3,91:1 rear end ratio with all new bearings
Carbon fiber prop shaft from Precision Shaft
Custom toolsteel flywheel
Spec 3-plate 7,25" clutch
McLeod hydraulic release bearing

Brakes:
Porsche Carrera GT ceramic 380mm brake discs all around
Porsche 996 GT2 front calipers all around
Carbotech brake pads
Steel braided brake hoses
OEM parking brake

Wheels and suspension:
KW Competition coiloverkit, 3-way adjustable
K-Mac camber-kit and rear beam bushes
Powerflex and Superflex front bushes
360Forged Spec 5ive 9,5x19" and 11x19" with brushed titanium finish
255/35-19" and 295/30-19" tires

Other mods:
Twin 2 3/4" exhaust system built with Burns Stainless parts
SPA dual digital gauges below radio/CD-player
Tinted windows
Moved battery to the trunk
Removed alot of weight

Performance:
Aiming for 1000bhp at the crank.

Carrera GT brakes. I have the discs, will be combined with 996/997 PCCB calipers.


Custom made flywheel with Spec 3-plate clutch and ARP flywheel bolts.


Custom regrind camshafts.


Dual valve springs with alu retainers


Rotating assembly


Wastegate, Tial 60mm with V-band clamps


Garrett GT45R with Tial SS housing


The car after sandblasting



KW Competition coiloverkit



360Forged wheels on my Zafira VXR (wheels will get new outer lips to widen them)

[pinkpyro]

thats going to be a monster when finished. i like.

[vauxmaster]

Look forward to future updates!

[lee303]

engine sounds pretty mega! 32.5mm exhaust valves not quite sure what you mean when you say you're using a nissan rod journal though? are you going for the carbon porsche brakes? looking forward to some more updates

[Lugy]

You Scandinavians certainly don't mess about! That turbo looks big enough to move the moon!

[eggman]

mint!!! words do not describe how much i like your way of thinking

[Jack]

This is going to be EPIC!

[adaptec]

@lee303: The crank has a 85mm stroke original with 52mm rod journal. My crank is offset ground to a 48mm rod journal and therefore now has a 89mm stroke. Therefore I use Nissan spec connecting rods and bearings. This gave me a nice and small compression height on the pistons to give me a lightweight piston. Also gives me a 22mm piston pin in stead of the heavy 24mm original pin.

I will use the ceramic discs all around from a Porsche Carrera GT. I don't belive Porsche has made carbon brakes yet. I will use calipers from a 997 Porsche with ceramic brakes because they are a lot cheaper.

@Lugy: It can handle about 1300bhp so it will have nice conditions on a 1000bhp engine

[adaptec]

I have also removed the automatic height adjustment rear, the ABS system is gone, a LOT of plastic covers in the front is removed to improve the air cooling for the engine compartment, a lot of noise isolation inside the engine is removed, the aircon is removed etc. Less weight is better performance. On the brake system I hope to reduce the unsprung weight a lot even with bigger diameter brakes.

[lee303]

@lee303: The crank has a 85mm stroke original with 52mm rod journal. My crank is offset ground to a 48mm rod journal and therefore now has a 89mm stroke. Therefore I use Nissan spec connecting rods and bearings. This gave me a nice and small compression height on the pistons to give me a lightweight piston. Also gives me a 22mm piston pin in stead of the heavy 24mm original pin.

I will use the ceramic discs all around from a Porsche Carrera GT. I don't belive Porsche has made carbon brakes yet. I will use calipers from a 997 Porsche with ceramic brakes because they are a lot cheaper.

ah right, get you now, thats pretty awesome, proper engine engineering will be very intetrested to see how it all comes together and the final output
and yeah, my bad on the brakes, should stop it pretty damn welllmao

[Adam]

im noticing quite a few peeps are using the 997 or 996 iirc calipers....how would u go about fitting these calipers to a pair of 330mm discs on a .........cav lmao

[mikegray]

Awesome. Really looking forward to the progress.

295/30-19.....

Good luck with the build!!

[adaptec]

@Adam: What does iirc mean? The front brake caliper I will use is from a 997 with 380mm disc. I have 380mm disc in front. The rear caliper is from a 997 with 350mm disc. I have a 380mm disc. I must make the brackets anyway so I don't see a big problem in fitting this. I will also need to make new bells for the brake discs. The rear bells will be made with OEM inside diameter and width so that I can use the OEM handbrake assembly.

[Rysee_sri_130]

If I Recall Correctly

[adaptec]

.

[adaptec]

im noticing quite a few peeps are using the 997 or 996 iirc calipers....how would u go about fitting these calipers to a pair of 330mm discs on a .........cav lmao

You have to make new bells for the brake discs and you need a custom bracket to mount the caliper. Nothing mysterious about it:P

[chip]

Very cool mate

[adaptec]

Hi Chip! Thanks

[DaveB]

That is some serious **** Be nice to see some serious modifying to an LC rather than just bufty stuff

[adaptec]

Today I received my Porsche Carrera GT brake discs They weigh less than 4kg each!

[NotNormal]

I'm baffled as to why you based this project on a Lotus Omega as all the specific Lotus parts your not actually gonna be using. Surely it would have been cheaper to use a base model Carlton

All the best and look forward to the results (although if I were you i'd be using the LC block as its stronger )

[adaptec]

I'm baffled as to why you based this project on a Lotus Omega as all the specific Lotus parts your not actually gonna be using. Surely it would have been cheaper to use a base model Carlton

Well, I want the LC look, LC interior, LC rear axle etc. Therefore I use a LC as base car. The car didn't cost me much either. I was also supposed to keep the LC brakes and wheels, but when I got these brakes I had to change my plans.

All the best and look forward to the results (although if I were you i'd be using the LC block as its stronger )

I have a LC block actually I just forgot because I was planning to use a C30SE block at first, but then I got a LC block in stead.

[escort1989uk]

Wicked Can't Wait 4 The Build 2 Start

[adaptec]

Can't wait my self :P
I guess that most of the car, except engine and tranny, is ready within a month. But there is a whole lot of work in the engine compartment before it fires up. I can't afford paint this winter so it'll have to wait a year. But I hope to do some driving next summer.

[Brian_S]

Brilliant project! Look forward to seeing the engine coming together.