Elan Kit car

[surfboardfiller]

I have been collecting parts for the last 2 years so this isn't really a new project but it is the start of the build and all the problems that can provide to my quiet and eventless life.

I just brought back my New Elan Bodyshell from deepest darkest Somerset yesterday and giving consideration to galvanising my brand new chassis as it sits naked on the floor.

The criteria to this unpecidented M100 project is to build a car:

with better accelleration and stability in every aspect, with ride and comfort on normal road conditions the prime focus.
Powered to 300 BHP (aprox) reliably.
Beat the Elise in all aspects of performance useablility and comfort.
Retain the look style and spirit of the M100 package.

This may chage but should be fun anyhow.

[Monty]

Bloody hell, another great project

[surfboardfiller]

The project as it stands...

[Nige]

That's a view I may yet become familiar with.

Going to be a left hooker then Phil? And do I spy sills on your shelf .

[surfboardfiller]

Going to be a left hooker then Phil? And do I spy sills on your shelf .

Not sure... On both counts. I have the sill trim on the shelf but the yellow bits are doors from the F Cat (recently sprayed) rear bumper (DaveEds) Bootlid (BobBrown)

Sills are an integral part of the car tub and don't come off. They contain the steel box section 'outriggers' that make it the stiffest convertible chassis built to it's day. (Geek'R'us)

[GeoffSmith]

…giving consideration to galvanising my brand new chassis as I sit stark bolleck naked on the floor.

I would have thought that the heat would distort it - maybe better to consider hot zinc spraying.

[surfboardfiller]

…giving consideration to galvanising my brand new chassis as I sit stark bolleck naked on the floor.

I would have thought that the heat would distort it - maybe better to consider hot zinc spraying.

Why? Esprit chassis were Galvanised, surely the job is pre heated before it's dipped to stop distortion.

Spraying won't get into the box sections.

[MattDon]

ive been dreaming of this for a long time, if i had your skills id do it in an instant. will be keeping a close eye on this. any thoughs on engine's? i wondered if a nice aluminium v6 could be made to fit, something like the jaguar 3.0, then you could even look at the 4x4 system.... seems like over kill but interesting.

[addict]

the engine and gbox from the focus rs would be a major pipe dream of mine can any one say 300bhp

[surfboardfiller]

ive been dreaming of this for a long time, if i had your skills id do it in an instant. will be keeping a close eye on this. any thoughs on engine's? i wondered if a nice aluminium v6 could be made to fit, something like the jaguar 3.0, then you could even look at the 4x4 system.... seems like over kill but interesting.

Been thinking about this and realised I have the 3D CAD for the Jag V6 and it's drive train, (I have the whole car) but I don't think it will fit. The Elan is Tiny.

I have bought a crashed car so I now have a complete front subframe and all the interior mechanical bits I could possibly need.

[MattDon]

thats a shame, i think of the elan as a GT car and a nice V6 would finish it off well and being all aluminium id have thought the weight difference wouldnt be huge. i wouldnt change my elan for anything (that i expect to be able to afford this lift time) but it would be nice to have an interesting engine note. Im guessing a straight six wouldnt be any better, i cant see many being usable in FWD. Is there more space in the rear? looking forward to this project. just wish i had a fraction of your talent and/or resorces.

[TrueBlue]

woo! big ups....respect!

[surfboardfiller]

Being stripped to reveal the tub is badly corroded along the sills and cracked into the Battery compartment



Tub being removed form the rolling chassis after a lot of hard work cutting sections out arround twisted sections of chassis



Bent chassis is revealed and removed from the front end after some advice from Mr Smith



New stage 2 chassis pre coated in Dinotrol



New tub with sprayed internal sections before the fittings and fasteners had been installed. Waiting to be fitted to the new chassis.

[HJ2]

Nice!

[Doug]

I like the kit car idea - just noticed the thread.

You may just need a bulge in the bonnet to cover over a transverse 6 cylinder???

would a VW VR6 work? are they FWD or RWD? I don't know their reliability or BHP potential though -- just came to mind as I was thinking to myself, "what 6 cylinder might fit under the bonnet with a shoehorn and grinder wheel...?"

[surfboardfiller]

I looked at the Jaguar V6 based on a ford block and it was a bit too tall, I'd have to dry sump it at least. Not much room in there, I'm still looking.

[surfboardfiller]

Old tub sripped and cut up ready to go to the tip. Windscreen removed intact!


I cut off the front firewall as these are no longer available and I have decided to make a RHD car from my new LHD tub!


Corroded Sill

[ashm]

Corroded Sill

Ouch - she may not have had that much time left anyway then...
Adam

[surfboardfiller]

No, the whole length on both sides are corroded and I had to cut the floor getting it of the twisted chassis. New tub is the best thing.

I have had a good look at a solution for other cars though.

The chassis was the old type so I had to replace the rear engine mount and the whole rear suspension system on the right is really twisted up. Nothing salvage able bar a calliper maybe.

Keeps me busy though!

[surfboardfiller]

New chassis is now bolted to the front end chassis and gear box. Although this sounds like 5 mins work it was a hard job after a long time sourcing the engine mount components as one I had from Dave T's car had slightly bent crash plates (trunnions). And keeping the whole front end in 1 piece whilst removing the chassis was a bit un orthodox to say the least.

I had a nightmare of a time sorting out the gearbox mount as the chassis was the early 5 degree type and I'm upgrading to the jogged 2.5 degrees. So fixing points for most things are different. The rear suspension system will have to be S2 as I can be sure it has all the SE upgrades consolidated.

I managed to replace the fuel lines I had to cut to remove the tub and a few other bits but I'm finding it harder to get things from Lotus now and feel everything is worth saving if possible and worth ordering asap just in case I get the last one.