XIL - A Rolling Project

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Re: XIL - A Rolling Project

Postby cliff » Sun 10.05.2015, 01:00

dapinky wrote:I used to have an engine stand like yours


Cheap and available. :D :D
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Re: XIL - A Rolling Project

Postby cliff » Sun 10.05.2015, 01:04

Ian T wrote:Having just done it, I can vouch for it being possible


Great write up, took me less time to take the engine out though. :D

Seriously, I thought the master cylinder was tricky, well done
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Re: XIL - A Rolling Project

Postby Ian T » Sun 10.05.2015, 16:45

I'm rather hoping that I don't regret selling my engine crane - it had been so long since I last used it that I decided to flog it and just keep the engine lifting bar I've got that goes between the tops of the inner wings. Fine on an Astra but no use whatsoever on an Elan...

I really should finish uploading the photos to that write up and then can transpose it onto the wiki.

Master cylinder does look tricky to get at, just everything else in the way. I wouldn't much fancy removing the servo, but guess that once the other stuff has been removed it's not that bad to do.

Ian.
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Re: XIL - A Rolling Project

Postby cliff » Thu 04.06.2015, 08:48

Cylinder head is off.

P6031233.JPG


Looks like someone has used radiator sealer at some time in the past as a few of the water passages are clogged, the rest is not too bad.

P6031236.JPG


After a quick clean.

P6031240.JPG


Bores are in good condition for 166k miles.

P6031241.JPG


Cylinder head, again not bad for the mileage.

P6031242.JPG


Engine ready to go for rebuild, stripped like this, it is surprisingly light, I can move it by myself without any problem.

P6031238.JPG


Gearbox cleaned and ready to go to Alan Voigt to have the third gear synchro looked at.

P6031245.JPG


Next stop steering rack.
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Re: XIL - A Rolling Project

Postby cliff » Sat 06.06.2015, 10:13

It's out, not without a certain amount of bad language though.

P6051281.JPG


The lower uj would not come off the spline so I had to remove the RH raft as well as the prongeron. It is still stuck on there so I will soak it for a while in penetrating fluid, if that doesn't work, I will get the guy doing the overhaul to remove it.

More grime and corrosion.

P6041257 (1).JPG


The headlight motors will be rebuilt so everything has been stripped out for cleaning and refurb.

P6041258 (1).JPG


P6051264.JPG


The RH engine mount looked good from the top but underneath is a different story, that won't be going back on.

P6051273.JPG


The brake pipes had to be removed to get at this corroded bit, probably caused by brake fluid eating the paint, but it is cleaning up pretty well.

P6051283.JPG


The bottle is there to catch the fluid from the master cylinder and Alfa flywheel bolts make great blanks for the forward BMC ports.
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Re: XIL - A Rolling Project

Postby cliff » Sun 07.06.2015, 22:10

I was thinking of taking the clam off and having all of the removable metalwork blasted and powder coated but there has been enough project creep already especially as have now dropped the LH suspension to treat a little corrosion behind the upper raft mount.

Always a nice feeling when the cleaning treating and preparing is done. I used Granville Rust Cure for the first time, it does seem to work better than FE 123 and gives a much better finish.

Masked and primed.

P6071296.JPG


Humberside Paints matched the chassis colour pretty well and suggested an enamel type paint which they made in aerosol for me.

P6071299.JPG


The engine is back, honed, new rings, bearings and seals. Many thanks to Bryan at the Humberside Engine Centre in Scunthorpe.

P6061288.JPG


Head skimmed, valve stem and cam seals replaced, valves reground. Bryan did mention that the engine was very coked, in fact he was surprised it ran so well. All cleaned and sorted now.

P6061285.JPG


Engine block painted with POR 15 engine enamel. All of the brackets and attachments have gone to be either powder coated or galvanised. So it should all look pretty good when it goes back together next month.

P6071305.JPG
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Re: XIL - A Rolling Project

Postby Jamie N » Mon 08.06.2015, 09:13

Looking great Cliff, on course for the cleanest engine bay on the Forum :wink: .
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Re: XIL - A Rolling Project

Postby HJ2 » Mon 08.06.2015, 09:39

Wow, now i'm jealous!
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Re: XIL - A Rolling Project

Postby cliff » Tue 15.09.2015, 19:55

So, after some time away, I have finally managed get back to the UK for a few days, we have a new base in Lome, Togo so the commute just got a bit longer. Not much to update but have had a few things done.

P9151644.jpg


Steering rack and pump refurbished by SRE Hydrosteer in Dewsbury.

http://powersteeringracks.co.uk

P7031328.jpg


Starter motor refurbished by WNS in Scunthorpe, they mentioned that these motors are very reliable which is good news given how hard it must be to change it with the engine fitted.

http://www.wnselectrics.com/

P9151643.jpg


Flywheel skimmed then balanced with the new pressure plate by AMB engineering in Sheffield .

http://www.amb-engineering.com/

P7031327.jpg


Everything that was removed from the engine bay including the prongeron and mounting brackets have been powder coated or galvanized at Yorkshire Power Coating.

http://www.yorkshirepowdercoating.co.uk

The turbo and ac compressor will be going for overhaul as well. Everything was working when I removed them from the car but knowing how hard it is to access these parts normally, it was well worth having them done. I have also had new fuel, oil and ac pipes made up.

Time to put it all back together.
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Re: XIL - A Rolling Project

Postby cliff » Wed 16.09.2015, 19:47

Seem to have been busy all day with not much to show for it.

Oil cooler pipes were not in the best condition.

P9161646.jpg


Bit of cleaning and paint, much better.

P9161650.jpg


Steering rack fitted, a total pita to do on your own, had to unbolt the steering column to fit the uj. :banghead:

P9161649.jpg


Few p-clips and brackets fitted as well.

Lets see how tomorrow goes.
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Re: XIL - A Rolling Project

Postby dapinky » Thu 17.09.2015, 11:07

Looking good, Cliff.

Steering rack is on my list of jobs to do for the winter. I have a nice new S2 rack to fit, together with new lower UJ. I am not going to attempt it until I whip the engine out as it looks like a real PITA to do with it in situ. Does the prongeron have to come off? (or at least, would it be easier if I took it off anyway?).
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Re: XIL - A Rolling Project

Postby cliff » Thu 17.09.2015, 18:37

dapinky wrote:Looking good, Cliff.

Steering rack is on my list of jobs to do for the winter. I have a nice new S2 rack to fit, together with new lower UJ. I am not going to attempt it until I whip the engine out as it looks like a real PITA to do with it in situ. Does the prongeron have to come off? (or at least, would it be easier if I took it off anyway?).


Dave,

I had the prongeron off for powder coating anyway, I ended up dropping the RH raft for clearance as well. Must be a nightmare with the engine in, although probably better on a lift.
Last edited by cliff on Sun 20.09.2015, 18:51, edited 1 time in total.
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Re: XIL - A Rolling Project

Postby dapinky » Thu 17.09.2015, 18:46

Thanks Cliff - that's pretty well as I thought.... Engine will be out anyway, so dropping the prongeron (and raft) isn't a big issue (I think Its been up and down more often than a whores drawers in the past year or so anyway :shock: )
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Re: XIL - A Rolling Project

Postby cliff » Thu 17.09.2015, 18:49

Getting good at this now as well, left the prongeron loose and had both rafts on in about 10 minutes. :D
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Re: XIL - A Rolling Project

Postby cliff » Thu 17.09.2015, 18:56

Better day today.

BMC & pipes installed, spent a lot of time replacing conduit and tidying up the cable looms. Looks much better now.

P9171658.jpg


Newly powder coating prongeron and stays fitted. The before and after pics make it all worthwhile.

Before:

P5051192.jpg


After:

P9171655.jpg


RH & LH suspension fitted. It looks worse than it is as it was given a coat of aviation grade dinitrol last year.

P9171657.jpg
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Re: XIL - A Rolling Project

Postby Ian T » Thu 17.09.2015, 19:15

Lovely job Cliff, hope to see it sometime.:)
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Re: XIL - A Rolling Project

Postby cliff » Sat 19.09.2015, 18:34

Thanks Ian, I hope to finally make to some Lotus meets sometime. :D
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Re: XIL - A Rolling Project

Postby cliff » Sat 19.09.2015, 18:50

My throttle cable was in poor condition, I picked up a new one last time I was at Brammer Parts in Mettmann.

P9191659.jpg


Surprising easy to change, a simple clip on the pedal, prize out the old grommet, heat and lubricate the new grommet which comes as part of the cable, re-attach the clip and job done. The RH wheel arch liner needs to be off as well as there is very little room beside the BMC.

P9191660.jpg


Build an engine stand and start attaching parts.

P9191661.jpg


Last look inside for the next 160k. :)

P9191662.jpg


Head on and torqued.

P9191663.jpg
Last edited by cliff on Sun 20.09.2015, 18:52, edited 1 time in total.
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Re: XIL - A Rolling Project

Postby lotusgirlmarie » Sun 20.09.2015, 03:46

Truly amazing work!! Congrats!! :cheers: :clap:
Must....................Go...............Faster
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Re: XIL - A Rolling Project

Postby cliff » Mon 21.09.2015, 19:07

Thanks Marie, praise indeed! :bowdown: :bowdown: :D
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