Basis

The chassis is a Lotus Elise S1 with a stock Honda K20A engine, which was run in a Lotus Cup. The customer wanted me to optimize the engine calibration as well as to have a look on the setup.

Aim

The engine should get an engine calibration which let the engine operate in a most reliable condition. Also a 1D engine simulation was planned to investigate further options on the exhaust and intake side to improve the engine performance among the reliability aim.

Process

The engine setup was transferred into the 1D-engine simulation to see what will be the torque curve in the applicated engine speed range and applicated track profiles. For that also dynamic chassis model calculations were done to see how the engine speed and gear will change throughout the reference track. Based on that recommendation for both, the gear ratios and the engine setup can be done. One of the results was to change the intake manifold to adapt the intake path due to air piping restrictions according class rules.

Above mentioned recommendations were implemented into the engine setup, followed by engine health tests and a break in procedure. With the go from these two important steps the engine was tuned on track remotly for an application specific mix of reliability and performance.

Result

Customer reported me his engine never run so freed and smooth as now. He also stated compared to supercharged Elise S2 (Toyota 2ZZ engine) with up to 300 hp, there is almost no difference in performance. His PB (01:39.5 min, big layout) on the Anneau du Rhine circuit is now similar to the 460 hp Lotus Cup Elise's, 4 s faster then the best of his class and faster then Formula Ford. He is a very good race driver, in a well harmonized car, were the engine setup is one of the bits to success. I am very happy to support him.