Lotus Elan Central

by **GeoffSmith** » Sat 30.09.2006, 10:50

F1 LOTUS wrote:I can't believe you actually did this!

Me neither. I suspected a malicious newbie initiation prank like the old apprentice school:

We need something heavy to hold this on the bench. You, go and get a weight from stores. Apprentice returns 5 minutes later and asks what sort. Go and get a short weight. Apprentice returns 10 minutes later and says they haven't got any. Go and get a medium weight then. Apprentice returns 30 minutes later...... :lol:

Well done Paul and sorry for misjudging you so badly Brian.

Geoff

by **Doc Fizzix** » Mon 02.10.2006, 01:15

paulwatkins wrote:
If you take the bonnet off can you tell me its weight, please?

Brian, are you being serious?
Running the risk that you were, I've just jumped on the scales with my hood! To the amusement of my missus.

The weight was 7.8kg or 17.2lb.

That doesn't include the hinges, but does include the catch, spring, prop-up rod, screenwash nozzles and pipes and the lotus badge!!

WOW! I would have never thought that much, felt so light to me :bonk:

by **Fubar1764** » Mon 02.10.2006, 02:22

F1 LOTUS wrote:A good carbon version should save about 10 -12lbs, but at a cost of around $800 it's not particularly good value even though it's weight off the front and it's high up
Thanks for doing that

And still cheaper than OEM Lotus!

by **Specky** » Tue 03.10.2006, 19:24

Just saw this on Ebay

Would it help Paul

TTFN

by **Enright** » Tue 03.10.2006, 20:21

I wouldn't bother! :shock:

It had about 114K on the clock and was incredibly grotty and uncared for all round.
The muck that was on that engine had accumulated over a long period of time.

by **paulwatkins** » Wed 04.10.2006, 09:54

Thanks for the info Dave_Speck, but all the new parts I need are on order with SJ Sports and should be with me early next week. The reboring has been arranged for early in november. Then the rebuild can begin.

So when this is all over, I'll hopefully have a nice reconditioned engine. Just hope I can get it going again!!

by **paulwatkins** » Wed 11.10.2006, 13:44

Just an update.

All the parts arrived on friday. Having the piston sets and con-rods weighed today to work out suitable pairings.

The engineers have been booked for 30.10.06 for the reboring work - which will be done with the block in-situ.
When that is done, I can start rebuilding.

Been spending quite a bit of time cleaning up the engine bay while i've been waiting for the parts, and while it is so accessible. It's amazing how much grime builds up over time. I've got to say that wd40 is probably the best stuff for the job. I've tried various products, but they cant beat good 'ole wd.

by **paulwatkins** » Thu 12.10.2006, 07:39

Got everything weighed up yesterday.

If anyone wants to know, each set weighed in at exactly 964.0g.

That includes the 0.5mm oversize piston, rings, conrod with bearings, gudgeon pins and circlips.

Precision engineering!

by **paulwatkins** » Tue 31.10.2006, 09:25

GREAT NEWS!
The engineers came down yesterday to carry out the reboring work and it removed all the damage from the no 2 cylinder wall. It was a great success.

My fears of some damage remaining were not realised thank goodness.

Thanks go out to Price Bros of Avonmouth for their excellent work. I would highly recommend them.

Now to finish off cleaning the engine bay, then the rebuild can start.

Paul

by **Monty** » Tue 31.10.2006, 15:55

Thats good news Paul, keep the photo`s coming

by **Dave M** » Wed 01.11.2006, 05:56

paulwatkins wrote:So when this is all over, I'll hopefully have a nice reconditioned engine. Just hope I can get it going again!!

You'll be surprised on how easily it starts after all this work. I have always been pleasantly surprised on how mine started after the various projects (including my rebuild).

Glad to hear things are going well!

by **Doc Fizzix** » Wed 01.11.2006, 08:57

paulwatkins wrote:I've got to say that wd40 is probably the best stuff for the job. I've tried various products, but they cant beat good 'ole wd.

Yep, it is the best

Also, spray it on and let it soak for even better results

by **paulwatkins** » Wed 01.11.2006, 11:19

Here's a couple of pics following the reboring work.
I didn't take any pics of the actual work in process. I'm afraid I missed an opportunity there!

The boring machine was a superb piece of equipment. It took the guy about 1 1/2 hours to do all four cylinders. That involved re-boring, honing and then polishing each one. It was interesting to watch him at work actually.

by **Monty** » Wed 01.11.2006, 17:35

Paul,

hopefully in years to come i would like to do an engine rebuild :shock:

and i`m watching u`r thread for information. Could u post prices of parts and work carried out as u go, that`ll give me an idea to what pennys to save :-D

cheers
Jay

by **Dico** » Wed 01.11.2006, 18:02

Paul don't forget to order your'e yellow samco hose set

Looking good so far :clap:

by **paulwatkins** » Thu 02.11.2006, 10:45

Paul don't forget to order your'e yellow samco hose set

Thanks for the suggestion Dico.....I know what to get the missus for xmas now! :-D

by **paulwatkins** » Thu 02.11.2006, 11:09

Could u post prices of parts and work carried out as u go

Costs I've incurred to date

1. Local mechanic to carry out compression tests and inspect problem - £35
2. Test 4 fuel injectors and service - £70.50
3. 1st home visit by engineers to try honing no2 cylinder - £88.12
4. 2nd home visit by engineers to re-bore all 4 cylinders - £150.70
5. SJ Sports - £91.40 - Made-up head gasket replacement kit, oil filter
6. SJ Sports - £393.82 - +0.5mm oversize pistons, piston rings, various studs and nuts for turbo/exhaust area, various gaskets required for plenum, injector housing, throttle body, thermostat etc

I've probably spent another £100 so far on 'bits and bobs' - engine oil, sprays, tape, nuts and bolts, tools etc

I still need to get some things - power steering fluid, distilled water, rust inhibitor etc etc, so I will update as i go. And I still owe for the replacement fuel injector I needed.

Monty, if you need a better breakdown of the parts I've purchased, just let me know.

Cheers, Paul

by **Monty** » Thu 02.11.2006, 19:44

No thats great Paul, keep up the good work :smt023

by **paulwatkins** » Tue 28.11.2006, 12:19

Got myself the following:
1. samco hose kit - in blue
2. just ordered the Peco s/s exhaust.
3. Dave's shortshift kit
4. Sold shifter mounts.

I have decided to change all the hose clips for the Jubilee stainless steel clips. They are quite pricey, but I reckon its a proper job!

I am going to order some manifold paint to coat the exhaust manifold and the cast iron downpipe section (I think its the cat housing...may be wrong though). The ad for it looks like a good finish, but time will tell i suppose. At $10, its worth a try!

I removed the alternator last night - what a flippin job that was! Why wasn't the alternator positioned so that the bottom pivot bolt could slide out easily without hitting up against a metal strut, and thus relieving the need to remove the bottom bracket?

The bolts holding the bracket were so tight - it was unbelievable. I couldn't get an extension bar on the ratchet to apply more leverage. Ended up placing a long bar on the ratchet from above and hitting down with a hammer. One swift strike was enough to start it off.

Also drained the fluid from the gearbox. Any tips and advice for pouring the replacement oil through the speedo hole? I took 2l of fluid out, is this the correct volume?

Going to get the starter motor off tomorrow and finish sprucing up the rear of the engine.

Anyone need some pics of any engine bits now that I've got easy access around it? Let me know if you do.....

by **Enright** » Tue 28.11.2006, 13:28

Here you go - all you could ever want to know about changing your transmission fluid.

But the short answers to your questions are - a funnel and a long bit of tube, and just slightly less than 2 litres.

Edit: I followed this excellent write-up from the repairs section.

Lotus Elan Central

Engine rebuild project following blown piston

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