Project Black

[par]

Starting to use the dark winter nights to make some progress with the Elan but project creep has already reared its head. I hadnt planned to replace the oil cooler but when I removed the bumper I discovered it was totally clogged, suspicion was an oil leak which was trapping all the road dust and dirt.


I had the hoses and cooler cleaned and pressure tested and there is a very small crack in the matrix so need to source a replacement, just weighing up the new versus second hand at the moment as the shopping list seems to be getting longer.

Removed the clamshell, some of the fasteners came off a dream and others were just blobs of iron oxide that might have been nuts at some point in time (dremel time). Lotus must have got a good deal on washers when you see the amount used as spacers in some areas.


Clamshell being removed provides some really good access and the chassis is in good shape, no doubt the coating of oil from the weeping oil cooler has helped There are a few spots of rust which will be treated with POR15 once I have degreased and cleaned as much of the chassis as possible.






I have got a new set of front suspension to fit which will match the rears that were fitted when Scott owned the car, also considering getting all the suspension parts removed, media blasted and powder coated while I have such good access.


Where will it stop

[Rambo]

Will it ever get back on the black stuff ? It could end up like Project Dico

[epipete]

I like that piece of wood bracing the clam - good idea, I hadn't seen that before

Though, I don't think much to the idea of installing a TV in there

[Rambo]

I like that piece of wood bracing the clam - good idea, I hadn't seen that before

Colin Chapman designed it

[Jamie N]

Will it ever get back on the black stuff ? It could end up like Project Dico

Not a chance!, this mans skills will see it back on the road in no time at all. Where is the rex Steven?, cant see it in any of those pics above .
Great work BTW .

[Scott J]

Coming along nicely, great work.

[lotusles]

I like that piece of wood bracing the clam - good idea, I hadn't seen that before

Colin Chapman designed it

Nope, if Colin was involved it wouldn't have been a new piece of wood. He was too tight!

[Rambo]

Starting to use the dark winter nights to make some progress with the Elan but project creep has already reared its head. I hadnt planned to replace the oil cooler but when I removed the bumper I discovered it was totally clogged, suspicion was an oil leak which was trapping all the road dust and dirt.


I had the hoses and cooler cleaned and pressure tested and there is a very small crack in the matrix so need to source a replacement, just weighing up the new versus second hand at the moment as the shopping list seems to be getting longer.

Removed the clamshell, some of the fasteners came off a dream and others were just blobs of iron oxide that might have been nuts at some point in time (dremel time). Lotus must have got a good deal on washers when you see the amount used as spacers in some areas.


Clamshell being removed provides some really good access and the chassis is in good shape, no doubt the coating of oil from the weeping oil cooler has helped There are a few spots of rust which will be treated with POR15 once I have degreased and cleaned as much of the chassis as possible.






I have got a new set of front suspension to fit which will match the rears that were fitted when Scott owned the car, also considering getting all the suspension parts removed, media blasted and powder coated while I have such good access.


Where will it stop

Fancy a weekend or two at Hotel Rambo ??

[lotusles]

Just a simple question, how long does it take to remove the clamshell? either novice or VM time.

[Giniw]

It doesn't look so hard, except that if I remember well what I read in the workshop manual there is a part that is glued, so I guess it is still a little bit tricky.
Anyway, I would be curious to know the answer, too.

[dapinky]

Like most jobs on an elan, removing the clamshell isn't tricky - except some of the fastenings may have rusted up a bit, making the whole thing take far longer than it would with clean fixings.

When I did mine I replaced all fixings with stainless items to make it easier in the future.

If the wheelarch liners come off easily it is far quicker than if you need to fight with those fixings - likewise the 'A' panels (where they bolt to the sill), then the front bumper - all those need to come off first to get to the actual clam fixings - oh, and the headlamp motors.....

....the actual clamshell bolts are straightforward, and the process is as per the WM.

The only 'glue' is a thin strip of sikaflex between the clamshell and bulkhead - just cut it away with a stanley knife.

With all good nuts/bolts i would expect to be able to remove the whole lot in a couple of hours - but with rusted ones it could easily take a day to do.

[Scott J]

Steven, Cambelt change is long overdue so add that to your list of jobs whilst you've got easy access to the engine.

[Rambo]

And don't forget the tensioner/idlers, water pump, PAS belt alternator belt etc...

And you may as well get the alternator, PAS pump, steering rack refurbished at the same time

Then some new plugs, ignition leads, coils....

[Giniw]

dapinky > Thanks a lot

(Rambo > )

[lotusles]

I notice that the turbo and shield are polished, is this standard or does it suggest a recent removal etc? It does not appear to be easy access to do in situ.

Also, what is the standard colour of the spark plug cover? mine is metallic blue, is that standard or customised?

[par]

Like most jobs on an elan, removing the clamshell isn't tricky - except some of the fastenings may have rusted up a bit, making the whole thing take far longer than it would with clean fixings.

When I did mine I replaced all fixings with stainless items to make it easier in the future.

If the wheelarch liners come off easily it is far quicker than if you need to fight with those fixings - likewise the 'A' panels (where they bolt to the sill), then the front bumper - all those need to come off first to get to the actual clam fixings - oh, and the headlamp motors.....

....the actual clamshell bolts are straightforward, and the process is as per the WM.

The only 'glue' is a thin strip of sikaflex between the clamshell and bulkhead - just cut it away with a stanley knife.

With all good nuts/bolts i would expect to be able to remove the whole lot in a couple of hours - but with rusted ones it could easily take a day to do.

Pretty much how I would have summed it up. I had previously replaced the wheel arch liners with stainless fasteners so that part was easy. Hardest part was the 'A' panels as the fasteners were so badly corroded and limited access and I had to accept some sacrificial damage to the fibreglass lip where the lower fasteners are on one side to get them removed. Clamshell fasteners were actually in good condition so quite straightforward and the wooden brace allowed me to move on my own without another pair of hands.

[par]

Will it ever get back on the black stuff ? It could end up like Project Dico

Not a chance!, this mans skills will see it back on the road in no time at all. Where is the rex Steven?, cant see it in any of those pics above .
Great work BTW .

Target is to have it all back together in April (not committing to April Fools day though).

May have to enlist some support from a local expert at some point - nudge nudge Jamie

Dont be concered around the CRX its not gone anywhere, it is doing its bit by providing protective storage for the front bumper and a few other parts.

[par]

Steven, Cambelt change is long overdue so add that to your list of jobs whilst you've got easy access to the engine.

And don't forget the tensioner/idlers, water pump, PAS belt alternator belt etc...

And you may as well get the alternator, PAS pump, steering rack refurbished at the same time

Then some new plugs, ignition leads, coils....

Cambelt, tensioners, water pump, belts are all on the list. Steering rack refurb is being considered. Alternator is fairly new I understand so isnt on the list at present, hadnt even thought about the PAS pump - need to stop reading this forum as the parts bill keeps on increasing!

[par]

I notice that the turbo and shield are polished, is this standard or does it suggest a recent removal etc? It does not appear to be easy access to do in situ.

Also, what is the standard colour of the spark plug cover? mine is metallic blue, is that standard or customised?

Heatshield was removed to polish, it is only held on by 3 bolts if I remember correctly, the other parts were done in situ when the clamshell was still in place. Quite a satisfying job to do for little cost. I assume the plug cover is black as standard, I certainly havent changed it.

[Rambo]

Steven, Cambelt change is long overdue so add that to your list of jobs whilst you've got easy access to the engine.

And don't forget the tensioner/idlers, water pump, PAS belt alternator belt etc...

And you may as well get the alternator, PAS pump, steering rack refurbished at the same time

Then some new plugs, ignition leads, coils....

Cambelt, tensioners, water pump, belts are all on the list. Steering rack refurb is being considered. Alternator is fairly new I understand so isnt on the list at present, hadnt even thought about the PAS pump - need to stop reading this forum as the parts bill keeps on increasing!

Sorry, just stirring

PS I forgot the rear brake upgrade and Jeemys hubs