Breathing new life into an old car

[Giniw]

Wow!

[Relevance]

Forget the Elan, please please please show more pictures and tell us about the NSX.

Going back to this, I didn't get any new pictures but I did get more info. 3 owner car, all original everything, ~7000 miles

[Relevance]

Met with the guys again last night and got some new pics - went through the parts book too and came up with a plan. First, shopping for parts, lots and lots of parts. Once I have everything I need the engine is going to come out and the current suspension is going in the trash (tech said he doesn't think its worth blasting it to see if it is salvageable - picture below) depending on how everything is going at this point, I'll probably have it sent out for a fresh coat of paint. Provided we don't encounter other major headaches along the way then we'll be able to start reassembly, by then I should have a title from my state. Still not sure if the car will need to pass an initial inspection for me to register it as a "antique" car (no registration or inspection required ever again) but fingers crossed I will not need to.

Brief rundown of parts required - I have been in contact with John C/M100-NC about these and he is taking a look - this list is also not fully inclusive as there were way too many individual parts to list out

-BODY
Seals, Soft Top + rear window, License plate frame, Taillights

-ELECTRICAL
Horn ,Turbo Gauge

-BRAKES
Front Caliper Rebuild Kit, Rear Caliper Rebuild Kit, Brake Lines

-ENGINE
Wire set, Plugs ,CAS, Alternator. Oil Pan, Water Pump, Thermostat, mostly every gasket, Oil return lines, idler pulley, crank seal, Fuel Filters, Radiator hoses

-SUSPENSION
Pretty much everything, front and rear.

[Rambo]

You'll need to add new brake discs, pads, cambelt, tensioner, idlers, associated other belts, tyres etc... to the growing list.

I wouldn't be at all surprised to find an HG kit too.

[Relevance]

Oh don’t worry, they’re on there. My current list is over 100 parts long and I didn’t want to clog up the post with every single one of them

[TorqueHorse]

Oh wow, you've got yourself a real project now! Once you get a quote on the shipping for all those parts you might find it cheaper just to ship a whole other car over

Those rusty bits do look toasty, but I also continue to be amazed at how Toby wrings life out of scary scenes https://youtu.be/Vp_d_QsIeQ0?t=581
Good luck getting your suspension in shape quickly, either way!

At the beginning of the year, I was able to pick up a replacement set of front calipers from RockAuto for cheaper than a rebuild kit. However, I just looked and can't find the same ones I got available anymore . (You are looking for 1989 PONTIAC LEMANS 2.0L 122cid L4 - and you have to double check they are for the VENTED DISC and for the two liter engine) They might pop up again in the future, or it still might be cheaper to get a set sized for the solid rotors (piston and sliders should still be the same size though) and cannibalize the parts to rebuild your calipers, than buying a dedicated rebuild kit. But its also more headache, and might not be right 100%, so its just an option if you find yourself looking for nickels to rub together after you buy all that other stuff. Or maybe you just use it as an excuse to upgrade to the PNM/Hi-spec ones

[Relevance]

Oh wow, you've got yourself a real project now! Once you get a quote on the shipping for all those parts you might find it cheaper just to ship a whole other car over

Those rusty bits do look toasty, but I also continue to be amazed at how Toby wrings life out of scary scenes https://youtu.be/Vp_d_QsIeQ0?t=581
Good luck getting your suspension in shape quickly, either way!

At the beginning of the year, I was able to pick up a replacement set of front calipers from RockAuto for cheaper than a rebuild kit. However, I just looked and can't find the same ones I got available anymore . (You are looking for 1989 PONTIAC LEMANS 2.0L 122cid L4 - and you have to double check they are for the VENTED DISC and for the two liter engine) They might pop up again in the future, or it still might be cheaper to get a set sized for the solid rotors (piston and sliders should still be the same size though) and cannibalize the parts to rebuild your calipers, than buying a dedicated rebuild kit. But its also more headache, and might not be right 100%, so its just an option if you find yourself looking for nickels to rub together after you buy all that other stuff. Or maybe you just use it as an excuse to upgrade to the PNM/Hi-spec ones

Firstly, thanks for the youtube link! I was having a hard time finding a before and after to use as a reference for mine, maybe it can be saved after all. I've been doing some shopping on rock auto, mainly for engine parts since its definitely the cheapest place I've found for them so far, going to go through the rest of the cross reference list on there soon now that I know the calipers can be so cheap! So far suspension have been the only hard parts to find stateside, but the technician doing the work has a little bit of insider info about somewhere we might be able to get the parts from I have a few other tricks up my sleeve for getting this resto done too but we will not really be starting until I have all of the parts in hand.

[dapinky]

Like has been said for the front callipers, the same is true for the rear......

..... I bought a pair of rear ones for far less than the cost of a rebuild (and even then, the pistons are NLA so I would have had to use old ones). With shipping to UK it was cheap, so for you it is a no-brainer.

It won't apply to you as you'll be replacing both, but it is important to know that the RHS calliper for the Olds Cutlass Supreme fits the LHS on the Elan and vice versa.

[Relevance]

Thanks Pinky and TorqueHorse for the caliper advice! Definitely going to grab parts bin parts wherever possible, especially those from US cars that will be both easy and cheap to find.

In that same vein I'm attaching pictures from my "parts needed" spreadsheet in case there are other parts that weren't on the GGLC/ElanM100.com cross reference lists or if anyone has general info regarding finding these parts. ALSO: these lists are incomplete and contain a mixture of critical "need to have" components like suspension components and "nice to have" components like a license plate plinth. Some parts may have been missed, others may have been listed and I will not end up needing them - only time will tell. I purposely left all of the hardware associated with these parts off of the list to avoid clogging it up even more.

[dapinky]

I'll have a look at your list later (I'm off to the garage for a few hours now!) - I have the lists from my project in a spreadsheet of everything I've spent, where I got it, and at what price...... you can rest assured I put a lot of effort into saving a pound where I could, so I could afford to spend money elsewhere!!!

[dapinky]

Right, I've had a squint at your list and have a few observations.....

.... firstly, it isn't for me to decide which bits you want to swap 'just for the hell of it', which bits would benefit from a change, and which bits should really be replaced as a matter of course....

.... but I have my own list of stuff that I change as a matter of course.

This includes all suspension bushes, ball joints and shock absorbers (which you have listed)...... however, springs are such solid chunks of metal that they rarely 'need' to be changed - especially if you are fitting new shocks with height adjustable platforms which will accommodate any 'sag' which has occurred over the past 30+ years...... This time I purchased GAZ shocks, but I have AVOs on my own car, and both are pretty similar in price and use, so the choice is yours (OE units are NLA).

I notice you have listed stuff like the rafts (and mounting plates) - the rafts themselves are NLA, but as they are a solid chunk of aluminium, they don't corrode, and usually will clean up very well. The plates may or may not benefit from a change, but that will depend on what they're like...... bushes should be replaced with rubber NOT poly (they are still available from SJs and SWL).

Front hub carriers also rarely "need" replacing (likewise the shock absorber lower yokes and ARB) as they are plenty thick enough to clean up for re-use - the wishbones themselves may or may not clean up enough to re-use, but you will be limited to SH parts unless you find some NOS on a shelf somewhere.

ARB drop links may or may not need replacing - I have about a 50% re-use history on them!

At the rear, you won't need the hub carriers - they are aluminium and will clean up well...... the stub axles should be okay, the shocks go in the bin, and the springs are as per the front (probably good to go again). ARB will clean up, lower wishbones are a lottery, same with upper links.

Rear wheel bearings are a VW Polo part (Febi bilstein 03674)

Brake hoses can be had from ebay for £100 for a set of 6 stainless braided ones.

Brake pads at the front are from a GM - not sure what the options are for you in USA - Rock Auto list a few different ones for the Pontiac LeMans 2.0L (I use Ferodo DS2500, but there are lots of others suitable), but the rear are Olds Cutlass Supreme - I used CENTRIC 10503770 from Rock Auto.

Front callipers are CENTRIC 14149007 & 14149008 - rears are CARDONE 184327 & 184328 (loads of cross-referenced options online)

For the cambelt job you need parts for the Impulse turbo....... I always buy from Rocks, but you may have other suitable options over there.....
Belt - Gates T169
Waterpump - US MOTOR WORKS US9220
Tensioner - GMB 4409070
Idler - GMB 4408840

Engine gaskets are Isuzu Impulse....... EXCEPT...... always use a genuine Lotus Head Gasket - most aftermarket ones designated as suitable for the Isuzu Turbo are NOT suitable for the Elan turbo, only the NA..... the waterways are slightly different and can cause early failure of the replacement gasket and warped head.

Be aware that some engine internals are not as used in the Impulse, so it is always worth an ask if you are looking at internals (pistons, cam followers, bearings etc) and the clutch is larger than the Isuzu ones.... often parts for the Elan are robbed from the 1.8 Isuzu lump, but not always.

Alternator - I fitted an Impulse unit to my car, a REMY 14971 (75A) which is a straight fit (electrically), but it is a few mm wider than the Lotus part and can be awkward to fit if you follow the Manual.... but very easy if you are doing the timing belt anyway and have the engine mount off..... or the suspension out...... or any other means of access! Note - the pulley is a larger diameter, so the unit will run slower, but still provide many more amps than required!..... BUT .... because of that, it requires a slightly longer belt to run it and still fit the unit in the 'standard' fitting range as allowed for on the mounting/adjusting bracket..... it needs a 4PK713 belt (I think mine was listed for a Citroen, but I just ordered by length).

As for the cooling hoses, I just bought a set of Samco silicone hoses as most that you can buy from anywhere are part of the original manufacturing run, so have been sitting in storage for 30+ years anyway. If you go that way, I have a list of all jubilee clip sizes that you need for them..... and it is always worth throwing away the heater valve and replacing it with a part from a Volvo 740. It is a straight swap, but uses a plastic body so will never rust....... https://www.aliexpress.com/i/1005003431391024.html

I also threw away most of the nuts and bolts, replacing them with stainless where suitable (in sufficient tensile strength, ie A4-80 grade, NOT A2 (or A4)-70).... some need to have a 10.9 grade and are replaced with new mild steel if they need to be that hard.

This is my shopping list (some things are missing, but it's pretty close to what I've bought).

shopping list 2.xls

(55 KiB) Downloaded 276 times

This is the suspension bolts in the sizes/grades you need:- (but you may need some extra ones along the way..... I always buy washers and nylocks in bulk for the common sizes (M6,8,10 &12)

suspension bolts.pdf

(413.94 KiB) Downloaded 248 times

jubilee clip sizes for Samco hoses

samcos.jpeg (50.83 KiB) Viewed 8189 times

[Relevance]

Dave - Wow! Thank you dearly for all of the info, very thankful this community is so supportive and willing to help their fellow owner. The more I can learn from all of you the faster this restoration will go!

Doing a lot of shopping around this week for prices but going to keep everything you outlined in mind as I make my lists

Cheers

[dapinky]

I ought to mention that although I got my newest set of HT leads (plug wires!) from Ebay UK, for you, Kingsborne Wires are a great product that I have on my other car as Doug (Tigerdog) did a group buy 15 years ago and bought a huge bag of them to Hethel for the Lotus 60th! IIRC they do a bit of a discount for LEC members, so it is best to call them rather than order online.

[tigerdog]

I ought to mention that although I got my newest set of HT leads (plug wires!) from Ebay UK, for you, Kingsborne Wires are a great product that I have on my other car as Doug (Tigerdog) did a group buy 15 years ago and bought a huge bag of them to Hethel for the Lotus 60th! IIRC they do a bit of a discount for LEC members, so it is best to call them rather than order online.

Looks like Kingsborne was acquired by Walker products earlier this year. https://www.walkerproducts.com/2023/05/ ... ire-werks/ Looks like they've dropped fitment for the Elan (for all Lotus products, actually.) I downloaded and double checked the ignition products catalog; jumps straight from Lincoln to Maserati. What a bummer!

[Fredjohn]

M100 leads still listed on Kingsborne website.

[tigerdog]

M100 leads still listed on Kingsborne website.

Quick! Buy a spare set!

[Relevance]

I ought to mention that although I got my newest set of HT leads (plug wires!) from Ebay UK, for you, Kingsborne Wires are a great product that I have on my other car as Doug (Tigerdog) did a group buy 15 years ago and bought a huge bag of them to Hethel for the Lotus 60th! IIRC they do a bit of a discount for LEC members, so it is best to call them rather than order online.

M100 leads still listed on Kingsborne website.

Going to give them a call tomorrow. Pardon the ignorance but are Kingsborne plugs superior to others or are the parts just incredibly hard to find?

[Saltire]

Just for the avoidance of doubt, Kingsborne supply the plug leads, not the plugs

I run them too, and they have been excellent over the last three years. The company (used to) do two sizes of lead - from memory 6mm and 8mm. I chose the smaller diameter, because I was concerned about ease of fitting in the Lotus application, but I believe others have used 8mm.

[dapinky]

Just for the avoidance of doubt, Kingsborne supply the plug leads, not the plugs

I run them too, and they have been excellent over the last three years. The company (used to) do two sizes of lead - from memory 6mm and 8mm. I chose the smaller diameter, because I was concerned about ease of fitting in the Lotus application, but I believe others have used 8mm.

Mine are 8mm - can be a bit awkward to force them into the plastic clips without risking damage, but that is probably just me being over cautious.

[tigerdog]

...but I believe others have used 8mm.

Smaug wears 8mm - they do not fit the original wire loom spacers, so other arrangements must be made.