Project Return The Orange Peril To The Road.

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Re: Project Return The Orange Peril To The Road.

Postby GeoffSmith » Thu 11.06.2020, 21:58

:clap:
Calypso Red S2 #417

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Re: Project Return The Orange Peril To The Road.

Postby Kipperozzy » Thu 11.06.2020, 22:20

Good idea and info CML :D
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Sun 14.06.2020, 13:38

I little bit of glass fiber tape reinforcement around the edge of the door cards the strengthen the repaired areas.

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3mm scrim foam bonded on ready the attempt some upholstery.

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Found the cause of the ignition not switching off. it was a dodgy ignition switch, think the female keyway is knackered.

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When fitted to the car it's intermittent at best, when taken off the column & key really push in it works reliably.
Last edited by CallMeLegend on Mon 22.06.2020, 16:34, edited 1 time in total.
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Sun 14.06.2020, 14:22

Pleased with how the repair to the damaged countersunk screw holes in the door cards went.

Passed a drill through 0.25mm larger than the home made sleeves to expose clean material, degreased & bonded the sleeves in place.

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Re: Project Return The Orange Peril To The Road.

Postby Rambo » Sun 14.06.2020, 20:24

GeoffSmith wrote:Will you be connecting up the heated seats and airscarf Mark


You are a legend Geoff :wink:
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Mon 15.06.2020, 13:28

Another small win today thanks to Rusty Wishbone here on LEC, speaker grill sorted.

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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Thu 18.06.2020, 11:04

Second attempt at the door card was more successful than the first attempt, my 17 y/o daughter did the sewing of these for me. The first attempt was big baggy, as you can see. Entirely my fault.

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Second attempt was way better, used a brush on contact adhesive this time. The spray on stuff I used on the first attempt didn't have any adhesion, it pulled away from the surface of the foam.

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Re: Project Return The Orange Peril To The Road.

Postby Rambo » Thu 18.06.2020, 12:46

That looks good. Well done to your daughter. :smt023
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Re: Project Return The Orange Peril To The Road.

Postby Mike Y » Fri 19.06.2020, 12:33

:clap: :clap: That's excellent work I bet you cant wait to refit them. :D
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Re: Project Return The Orange Peril To The Road.

Postby Rusty Wishbone » Fri 19.06.2020, 13:16

Nice job!
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Fri 19.06.2020, 15:13

Repurposed an old GM ignition switch today to use in the Elan. Belled out the old one to cross reference with this one, the original ones for the Elan are no longer available sadly.

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Had to salvage the old harness & crimp/solder of the flag spades.

Word of warning if you buy one from SJ Sportscars, despite being over £50 delivered & having a photo of the switch & loom on the page what you actually get is a 5pin GM switch, that has come from GM via Lotus. https://www.sjsportscars.com/parts-and- ... M6178S.htm
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Sat 20.06.2020, 18:48

Sadly it didn't work despite belling it out, non of the contacts show continuity when in "ign" posn
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Re: Project Return The Orange Peril To The Road.

Postby Brit-Car-Nut » Sat 20.06.2020, 21:06

The heavy gauge red wire should be the power from the Battery.
The light gauge red wire should probably be paired with the heavy red wire.
The black wire should be the power to the Ign Coils, and to the alternator.
The black/red wire should be the feed to the starter relay.

Can you jump the proper wire connectors to turn on the ignition? (red to red and then to black should turn on the ignition) and tapping the black/red should turn the starter.

If that works, then you either have the connections wrong or a bad switch.

You should use switch A082H6460H (£10.89) which has an "accessory power" connector that you could connect your radio or other component you might want to turn on without the key in the ignition position when the key is out, there will not be any power to that circuit, so you can't leave your radio on by mistake.

I can pull a new switch and tell you which terminal gets which wire. There are 6 connections but only 3 wires needed for ignition and start. The 4th connector is for the accessories and the other connectors are for US/FED circuits that you don't have.
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Mon 22.06.2020, 08:31

Carried out some final repairs to the door cards yesterday afternoon, these were in a bit of a pickle, this was one on the most rewarding jobs on the door cards so far.

One side was broken, but the part that was broken off was still there, so I cleaned it up for bonding & attached it using DP460, a bot of post bond cleanup, maybe mix some paint the same colour to touch in & I'l be happy with it as it's mostly hidden by the escutcheon.

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The other side however was a different story, the tin section was missing. So I decided I had to make one.

I took a mould from the repaired side using milliput.

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Then sound an old vac-formed Makita power tool box liner & cut out a flat section. Using a small hot air gun & heated the plastic, pushing it into the mould best I could, the resultant section was trimmed & bonded into place.

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Finally I cleaned off some of the original material & boneded i an overlapped doubler. Cleaning off the original material ment ounce the doubler was on the section in this area would be the same thickness as the original part.

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Needs a few hours in the oven (conservatory) to cure fully then it'll be cleaned up & painted the same colour, but again, it's mostly hidden by the lock pin escutcheon.
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Re: Project Return The Orange Peril To The Road.

Postby Saltire » Mon 22.06.2020, 10:59

:clap: excellent work, Mark
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Tue 23.06.2020, 10:59

The finished result on fabricating the missing section of door around the lock pin escutcheon is not by any means perfect, but I think it will suffice, given it's mostly hidden by the escutcheon anyway.

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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Wed 24.06.2020, 15:15

Thanks to Par on LEC I managed to get my hands on an original Elan switch, albeit with the incorrect connector on the end of the flying lead. Quite simple to cut the old connector form the original switch & solder to the new flying lead, also gave me the option to increase the lead length slightly.

The Red lead is the immobiliser "starter disable" circuit (I didn't have Black/Red, amateurish I'm afraid, but needs must. The loop in the connector is a simple jump lead to test the cable.

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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Thu 02.07.2020, 08:37

As the car is kept 65 miles away at the moment, during the week I have to concentrate on the jobs I can take home with me.

The gear knob & gaiter are not to my liking in the car.

The knob is worn out.

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The gaiter looks generally tired.

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The a new knob & gaiter are required, but first the original wire retainer had to be removed from the gaiter, this was a piece of steel that had never been painted, so was rusty. Time to give it a Deox C bath in the best Pirex bowl (women love it when you use kitchen equipment for cat stuff, try it).

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Followed by a good wash, dry, etch prime & some Black paint to protect it.

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A new gaiter has been source, to match the subtle paint colour.

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Had to get a new gear knob too, found a really scruffy Elise item that I set to with varying grades of wet & dry, followed by Dodo Juice Supernatural metal polish I had lying around. Needs a final polish to remove the last of the sanding marks.

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Last edited by CallMeLegend on Thu 02.07.2020, 10:57, edited 1 time in total.
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Re: Project Return The Orange Peril To The Road.

Postby Rambo » Thu 02.07.2020, 09:10

How will the square metal clip fit with your new gaitor ? It looks almost circular at the base rather than OEM square ?

PS looks like Stevo gave his knob some abuse :shock:
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Re: Project Return The Orange Peril To The Road.

Postby CallMeLegend » Thu 02.07.2020, 10:41

Rambo wrote:How will the square metal clip fit with your new gaitor ? It looks almost circular at the base rather than OEM square ?



It will fit the same no problems. My whizzo daughter will be on the case.
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