After over a year of development, testing and refining, we are finally ready to announce pricing for our intercooled turbocharger kit for the 2005-2011 Lotus Elise 2ZZ-GE. But what is a price if you don't know what the kit contains? This blog will highlight all of the components and fully explain the details of this turbocharger kit.
While we have always intended for the turbo kit to be an all-inclusive package, we have experienced delays with our Lotus specific engine management system. We did not want this to further hold back the release of the turbo kit so we are now releasing our Hard Parts Kit. The Hard Parts Kit consists of all the turbocharger kit components, MINUS the engine management system and any engine wiring harness adapters. In early Fall 2011, we will be releasing our Lotus Plug N Play Programmable EMS. This Hard Parts kit is ideal for someone using a stand-alone EMS, piggy back ECU, or reflash ECU that their tuner is comfortable using.
Earlier this year, we experimented with a non-intercooled setup in order to provide a lower cost alternative setup, but we decided that the price savings was not worth the sacrifice in performance. For this reason, we are offering our Hard Parts kit in intercooled form only. You can read more about intercooler testing here.
This kit is designed to be a complete bolt-on system that requires no special tools or permanent modification to the car allowing the vehicle to be returned to stock if necessary. Furthermore, all factory equipment is retained but the relocation of certain items is required for proper installation.
Here is a pictoral list of the contents of the Radium Engineering Hard Parts turbocharger kit:
1. Garrett GT2860
We have selected the Garrett GT2860 as the best fit for the 2ZZ-GE engine. This turbo offers very quick spooling along with ample air flow for up to 400hp. This turbo is water cooled and uses a special T3-flanged exhaust housing that has a custom Radium machined wastegate port for this application. Available in ball bearing as well as journal bearing for cost savings. Both have the same GT aerodynamics. This turbo kit has also been designed to be compatible with the Garrett GT3076 (Rated up to 550 Hp) should it be requested. All turbine housings are ceramic coated by Radium Engineering for a lasting finish and improved heat retention.
2. Internal wastegate actuator assembly
We had our own wastegates manufactured for this application (prototype shown in picture). These actuators are held in place with a custom laser cut nickel plated Radium bracket. These can be controlled with an electronic boost controller for driver or EMS controlled boost levels, starting as low as 7psi.
3. Radium cast stainless steel exhaust manifold
Our exhaust manifold is cast from 347 stainless steel. It is a bulletproof design and will easily hold up in even the most extreme applications. For a more in-depth look, see the individual item product page.
4. Exhaust manifold heat barrier
This thermal blanket is custom made for us by a company that holds the rights to several proprietary technologies. These same heat barriers are used on F1 racing engines, military helicopters and more. This protection drastically reduces under-hood temperatures and is a necessity for the kit. For more details, Read our Blog.
5. Radium cast stainless steel downpipe elbow with integrated internal wastegate swing valve
The downpipe is cast using the same 347 stainless steel and high tolerance investment casting process as our exhaust manifold. This critical part will not crack or deform under harsh conditions. It features an integrated 3" V-Band flange for easy installation of the exhaust system.
6. 3" stainless steel exhaust mid-pipe
This 3" exhaust pipe connects to the cast downpipe elbow and routes exhaust gasses to the muffler. It is compatible with the stock muffler and attaches to the factory slip-joint inlet (concept shown). This system is also compatible with other aftermarket mufflers that connect with the slip-joint the same as the factory muffler. We will be releasing a pipe with a high-flow catalytic converter option (for an additional charge).
7. Top Mount Air to Air Intercooler
Our intercooler is designed for the Elise engine bay. Because of the lack of space we chose the more efficient bar and plate core design with custom Radium cast aluminum end-tanks. It contains an assortment of bungs for sensors as well as an integrated GReddy style BOV flange. We are offering an intercooler air-flow upgrade kit separately, see details below.
8. Silicone couplers
Our custom 5ply silicone couplers are designed for efficient flow and packaging necessary for getting air in and out of the intercooler.
9. Radium billet oil return fitting for oil pan
This billet fitting functions similar to a banjo bolt. It allows oil from the turbocharger to drain back into the stock oil pan via the drain hole using a -10AN hose assembly. There is no need to uninstall, weld or modify the factory oil pan. This saves on installation labor and time. The fittings have been thoroughly tested in extreme driving conditions and has proven to work very well with either turbocharger option. For users with an aftermarket oil pan with ports already supplied, this fitting is not necessary.
10. Cold air intake system for turbocharger (Toyota MAF sensor compatible)
This air intake system draws air from the LH side air duct of the vehicle. This supply of cold air helps keep the intake temperatures dramatically lower in all driving conditions. This system is compatible with recirculation of the blow-off valve, as needed for accurate MAF metering. It consists of mandrel bent 6061powder coated aluminum tubing with custom silicone couplers. This part is in the final stages of production.
11. Synapse Engineering Blow off Valve
This is our favorite blow off valve on the market. It uses a superior piston design and works incredibly well at all boost levels and is very responsive. Read more about Synchronic technology here.
12. Radium coolant expansion swirl tank
This powder coated cast aluminum tank replaces the factory coolant reservoir. It mounts to existing studs in the center of the firewall adjacent to the factory ECU. Not only does this multi-chambered tank do all the things that the factory Denso tank does, it also features an integrated swirl pot helping to de-aerate the incoming hot coolant. Chambers shown in the transparent CAD render.
13. Radium 2ZZ-GE water hose relocation kit and turbo water lines
Because the Toyota 2ZZGE engines were designed for front wheel drive vehicles, most of the components are mounted backwards. These -AN hoses and billet aluminum fittings re-route and clean up the factory water lines for more efficient packaging. It also incorporates lines for the turbocharger coolant system. The custom billet fittings are anodized Radium green for appearance and durability. Thermal protection sleeving is also included for the hoses routed near the turbocharger.
14. All necessary gaskets, nuts bolts, T-bolt clamps, brackets, hoses, etc.
Every required nut, bolt, gasket, fitting, etc is included in the kit for a hassle-free installation.
We are releasing the base level kit at an introductory sale price of $6,195
Here are the available options for the kit:
1. Ball bearing turbocharger +$295 (GT2860RS)
2. Polished exhaust system: exhaust manifold, downpipe elbow, and exhaust mid-pipe +$495
3. Intercooler air flow upgrade kit +$450
This kit provides a dedicated custom air duct that channels fresh air to the intercooler from from the LH side vent of the vehicle. Also included is a 10inch SPAL electric pusher fan and fan shroud. These are installed on the bottom side of the intercooler. This kit is highly recommended for users in warm climates and customers participating in high performance driving events.
4. Relocation brackets for windscreen washer fluid bottle +$95
This bracket relocates the washer fluid bottle to the forward/left area of the engine bay. It provides mounting points for many accessories such as: Radium oil catch cans, Radium fuel pressure regulator, map sensor, boost solenoid, and E85 flex fuel composition sensor.
For the engine management side, we recommend the following that will help complete the installation:
-630cc Fuel Injectors (set of four)
-Radium Engineering Fuel Rail
-ECU Connectors (2005, 2006+) -Useful for constructing custom adapter wire harnesses for piggy back or EMS installation.
-Radium Engineering Surge Tank with upgraded fuel pump
-Radium Engineering Surge Tank installation kit for Lotus Elise (Frame rail mounted)
-Radium Engineering adjustable fuel pressure regulator
Over the next couple months, we will be working with aftermarket Lotus ECU tuners who are interested in supplying a factory ECU reflash tune for this turbo kit. This will open up another possible engine management solution, should the customer not want to go with a piggy back or stand-alone ECU. We will post updates on this aspect of the project as they develop.
Frequently Asked Questions:
When will the kit be available for shipment?
Radium Engineering is accepting pre-orders for the Hard Parts turbo kit starting immediately. Shipment is planned for mid August 2011. Please contact us at: firstname.lastname@example.org for details.
Do I have to remove my rear clamshell for installation?
We highly recommend removing the clamshell for installation.
Can I install this on my 2006 normally aspirated Lotus Exige?
Yes, however we have not test fit the kit on an Exige. If you are interested in installing on an exige, pleaes contact us and we will work with you personally and address any issues that may arise from the different body styles.
How difficult is the installation?
The Hard Parts kit has been designed to be 100% bolt-on, no special tools, fabrication, etc. are required. With the clamshell removed, installation can be done by someone with above average wrenching skills. However, the engine management solution should be handled by a professional.
Can you recommend a shop that can perform the installation and/or handle the engine management install?
Yes. We work closely with Portland Speed Industrieshere in the Pacific Northwest. They are capable of providing full installation, tuning, and engine management services. Radium Engineering does not perform installations.
How much power does the kit make?
The great thing about turbochargers is that they can easily be tuned to a wide variety of power outputs depending on fuel type and driving conditions. This should be left to the professional tuning the vehicle. The power output is not limited by the turbo kit, it is limited by the engine and drivetrain. We have not experienced engine or drivetrain problems on our shop car which makes a safe and reliable 300rwhp on 110 octane. With a built engine and related driveline mods, the power output could be pushed to as much as 500hp. The final power output number of your vehicle will be up to the tuner, and what they think is safe and proper for your specific vehicle.
What are the benefits over a supercharger kit?
If you are converting from a supercharger, you will immediately notice the large increase in midrange torque. Because of the lightweight characteristics of the Elise platform, Lotus was able to get away with this lack of low end power in its factory form.
Because turbochargers use wasted exhaust energy to operate, they are more efficient. More reliable power can be made because the engine does not have to work as hard to make the same amount of power.
Supercharger flow is dictated by engine speed. When an increase in power is requested a smaller pulley must be physically installed. Turbochargers do not require any hardware changes for a boost pressure change. A simple valve or solenoid can be routed to the wastegate and boost pressure can be adjusted based on EFI parameters, interior switch, etc.
Furthermore, with the flexibility of a turbocharger, power can be increased or decreased at specific locations or areas throughout the powerband .
Do turbochargers lose power at high elevations like superchargers?
Assuming an electronic boost controller with closed loop feedback is used and the turbo is not already maxed out, the wastegate will automatically compensate for higher altitude. Power will always be the same, no matter what altitude the vehicle is driving in.
Why are there many more supercharger kits nowadays?
One downside of turbocharger kits on modern cars is the lack of real estate, specifically in the Lotus. We have solved this by investing in top quality investment cast tooling that yields parts with shapes that are not normally achieveable with hand fabrication. We made extensive use of our FARO CMM arm and SolidWorks modeling to locate and shape parts strategically in the vehicle.
Aren't turbochargers too hot for the Lotus engine bay?
Luckily, the exhaust side of the Toyota engine faces the back of the vehicle. This allows the turbocharger to sit in the low pressure rear section of the engine bay that is able to allow hot air to escape out the rear of the vehicle and through the decklid. We also take full advantage of the factory air flow and ducting while adding our own heat management components such as thermal wraps, sleeves, coatings, ducts, shrouds etc.
Why are turbo kits so expensive?
Turbocharger kits are inherently more expensive than the average supercharger kit due to the added complexity and increased part count. However, the benefits of increased performance and tuning flexibilty that come with a turbocharger system are realized. Over the last year we have found ways to cut costs and make this kit affordable by comparing multiple vendor quotes and finding the best in business for quality, lead time, and cost. We have managed to keep this kit economical by carefully considering manufacturing processes and costs in all aspects of our designs. All of our components are geared for high volume production which also reduces costs.
Please send any questions to us at: email@example.com