Powerupgrade EX500 incl. new Supercharger R1900-TVS

Started on 20.06.2017

Performance Upgrade EX500 for Exige S V6 and Sport 350

Performance Upgrades with a supercharged engine is for sure
quite simply: increase the charge pressure until you get the
performance that is achieved and hope that the engine will solve
this massive mechanical and thermal wear out somehow.
And if it reacts with a massive engine damage,
the customer had bad luck. This is the simple method!

We have decided to upgrade with an more intelligent method:
The power should increase to 500 hp and 530 Nm by a minimum of charge-boost.
Also we take care of the lowest possible wear on all engine components
that can be achieved. The corresponding development process has taken our
experience for many months. After many different calculations, CFD flow simulations,
construction of different kinds of prototypes and countless hours on the dyno
we have now reached the goal of our development.

 

 

EX500

 

500 hp with a maximum charge-pressure of just
0.8 bar, a reasonable amount of internal motor
measures and a stable engine.

The focus of the development was to optimize the airflow
in the complete inflow tract, starting with the air filter and
its housing, via the air mass meter, and the throttle valve
up to the intercooler-housing between the charger and the inlet ducts.
This intercooler-housing must be a highly efficient charge-air-cooler,
but at the same time the inflowing air should pass it with the lowest possible
resistance and it should even get a distribution of the flow to all 6 cylinders.
If the charge-pressure is unevenly distributed over the individual cylinders,
The Cylinder with the largest inflowing air mass will also get the highest thermal wear.
The fatal consequences are destroyed pistons and valves.
The results of the CFD analysis have led to numerous tests  was successful.
The measurements of the flowpressure and –temperature at the different
intake ducts confirmed the positive results.

Considering the total efficiency of a supercharged engine
The efficiency of the charger cannot be forgotten.
The “Eaton” charger requires the highest efficiency at a driving-power
of about 60 hp. If you have to leave this comfort-area to go over to a raised
charger-rpm it can generate an higher charge pressure, but the own driving-power
will increase rather quickly by 10 ho or more.

 

TVS Map

 

In the finals of our development we generate up to
550 hp and 560 Nm, but also caused high engine wear
appearance. 500 hp therefore seem to be a “healthy” basis,
but for sure the beginning of future challenges!

 

 

EX500 (1)

 

Power-Upgrade EX500-Kit:

Key Benefits:

  • Reduction of the air intake temperature (cooled / uncooled) of approx. 35 ° C
  • Charge pressure loss by cooling system only 0.01 bar at 0,8 bar load pressure
  • Only a small additional weight (approx. 7.8 kg incl. Heat exchanger – without water)
  • Increased torque (130 Nm) and power (150 hp) to the standard vehicle

Phase EX500 consisting of:

  • KT500 Carbon Airbox System with K&N sports air filter
  • New Harrop TVS1900-Supercharger
  • Forged pistons
  • Forged con-rods
  • modificated pulley
  • Stainless steel manifold with optimized pipe lengths
  • 200-Cell Sports Catalyst HJS (Main Catalyst)
  • Oxygen sensor extension-cable
  • Optimization ECU-Software EX500
  • (ignition, injection characteristics and camshaft phase adjustment)
  • EX500 Decalset

EX500 water-to-air charge-cooling system consisting of:

  • Heat exchanger cooler in vehicle front
  • Electric water pump
  • Aluminum water tank for chargecooler
  • Complete aluminum intake manifold with integrated chargecooler and
  • injectior-holder, black anodized, revised for Harrop TVS1900 charger
  • water hoses

 


Lotus Exige,