Lotus E21 construction report part 17

Interim Report:
Something about Rear Crash Structure, ERS Battery, Exhaust System and Rear Wing

Pretty long time went on since my last post. Some work on uni, some work in Formula Student and a move into a new flat prohibited me working a lot on the Lotus. Nevertheless there are some news since the last report.

Where should I start? Probably it’s worth mentioning at the beginning that the gearbox is now finally fitted to the engine. This comes along with the finishing of the hydraulics pump/hydraulics system which sits on the right hand side of the engine beside/behind the oil pump.

After fitting the gearbox to the engine, I started working on the rear crash structure. Nothing very impressive or interessting to tell about it. With the fit of the rear crash to the gearbox, the car reached its full lenght of 507mm. It should actually be 508mm long, but one mm is within the acceptable tolerance (indeed it’s less than 0.2% deviation). Of course the rear crash structure is hollow to allow the fit of a working rear light. 🙂

Another work which was done within the last two month is the production and fit of the ERS-battery. Although the battery isn’t visible on the finished car, I produced a simple battery model, just as a “nice to have item”.

Next point on my (still endless long) to-do-list was the manufacturing of the exhaust manifold. Always a very demanding and not really liked work. For the first time in my modelling career, I produced an exhaust system, lacquered with a chrome spray. And it looks convincing. The system is already fitted on the car. And the packaging is stunning. I had quite a few problems to make the underbody fit to the car with the mounted exhaust manifolds.

Subsequently I started working on the rear wing. End plates and flaps are finished, DRS and beam wing are still under construction.

There are also some bad news. I had to grind off the whole cooling ducts in the side pods as they were too wide at the bottom. Coming along with this, my radiators are also worthless and need to be redesigned. Luckily radiators are not very demanding to design and build.

The car currently has about 3100 parts. About expected 2500 more to come.

Rear Crash Structure

Finished rear crash structure.

Gear Box with Rear Crash

Rear crash structure fitted to the gear box.

ERS Battery

ERS battery installed to the car. The battery will disappear after fitting the underbody.

Exhaust Manifolds unpainted

The raw and unpainted exhaust manifolds. Each pipe consists out of a steel wire as the core element wrapped with some layers of paper.

Exhaust Manifolds painted

Painting process of the rh exhaust manifolds.

Exhaust Manifold

The finished rh side exhaust manifold.

Car from felow

The engine area from below with fitted exhaust manifolds.

RH Exhaust Manifold

Rh side exhaust manifold.

LH Exhaust Manifold

Lh side exhaust manifold. There is a heat shield clearly visible to protect the power steering hydraulic line.


The underbody is waiting for getting fitted to the car.

Exhaust Manifold fitted

The lh side exhaust manifold with the fitted underbody. The packaging is extremely neat.

RWEP internal Structure

The RWEP internal structure. It’s a bit more complex as it looks from the outside. Each endplate consists from almost 40 parts.


RWEP vanes.


The rear wing in its current state.

Cooling Ducts

The destroyed cooling ducts…

At the end a nice video of the first try to fit the underbody to the chassis.



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About paulsf1

My name is Paul Bischof. I’m a student in mechanical engineering at the Technical University of Graz in Austria, expected finishing in February 2016. Since I was eight years old, I am building model planes out of paperboard. Since 2004 I scratch (that means building without an assembling set) Formula 1 and sportscars in 1:10th scale. The average time I need for such a car is around 400 to 700 hours within 4 to 8 months. One car has around 3500 up to 5000 single components. On this blog, you can take a look on my work and later, after my studies, hopefully you can see me in Formula 1.

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