Zetec In Baby Elan

[miked]

As a long term entertainment project to create a track day car I want to put the two litre Zetec in a S4 baby elan FHC with a lotus chassis. I would like to talk to anybody who has done it or who is contemplating. I have read (with interest) all the articles by Spyder with the plus two and the recent artical about the sprint. I have a lot of the parts to do it and am more intrested in the Lotus chassis way retaining more elan/plus two bits of the elan. Bearing in mind the chassis strengthening, drive train and brake mods etc etc.
This would be for track day use, not any serious stuff.


Anybody out there?

[riverkeeper]

Be a bit of a waste to do this to a proper elan , no ? Unless you've got a few bits to build one up as a 'Q' plate car. Agree that it would be an interesting car/ project though and have seen the Spyder(non running) prototype of a S4 FHC with a Zetec in it.

W.

[pereirac]

A BDA engine would be nicer and probably easier to fit in the 'standard' Lotus chassis

[miked]

W, You are right. This is a Heinz 57 collection of parts that I am bringing together. I was going to do a kit car and then dropped on the parts from a friend. It sound a better wasy to go as I am getting something with more character and saving an Elan. Others may disagree.
I have done the full elan restoration and want to keep it nice. The zetec looks like cheaper relaible power.

regards M

[GrUmPyBoDgEr]

Hi,
should be feasable if you use the original gearbox. Lots of work though. On top of what you have mentioned, you will have to consider the exhaust system, cooling system and engine mounting brackets. A suitable intake manifold for 45 DCOE's or fuel injection, flywheel & clutch, suitable starter motor, engine management unit, shorter oil filter, engine wiring harness & oil pan modifications.
The 2 liter engine, lightly tuned, turns the Elan into a lovely little beast!
Good luck,
John

[miked]

John,

I agree lots of fiddliing and thinking. I have been looking at all the raceline web site info' on the bits you mention. Also one of the mags had an artical about dropping a Zetec in a Cortina. This has advice about 1.8 escort bits like sump pan etc. I have the engine and carbs sorted and its still looks reasonable cost to obatin the other bits.

The most expensive bits I think will be the TTR bits for the diff output and the solid drave shaft etc.


Thanks Mike

[GrUmPyBoDgEr]

Hi Mike,
sounds like you are on the right track. You will also need the Escort water pump, which is designed to rotate clockwise.
I have reservations about the design of the very good looking "Raceline" water rail. The explanation for my resevations is complicated so if you intend going down that route please contact me.
I have the TTR drive train components, including Quaiffe LSD, fitted in my Elan; gives me a good feeling of security, the only possible weak point is my original prop shaft.
I only have experience of fitting the Zetec into a Spyder chassis but if I can be of any further help just shout.
Keep us posted on your progress.
John.

[GrUmPyBoDgEr]

PS
Have a word with Paul of "Dunnell Engineering" he has lots of nice goodies for the Zetec that work well in the Elan.
John

[lotuselanman]

What a fine man you are showing a bit of determination and dare to different.
Do what you will as long as nothing is cut or modified on the car that hinders it being returned to 'original'.
Obviously you have put a lot of thought into the swap as you already have or have plans to up grade the rear end.
Don't listen to the detractors, the 2ltr Z will have torque in abundance as well as an easy high HP figure.
I am doing a similar swap with a +2 that unfortunately is somewhat drawn out due to other project, hopefully I will be back onto the Z by the end of March, this year of course.
See ya, Les.

[miked]

Thanks Guys. Not starting it yet but am gathering bits and researching.

Les, it is a challenge and I will try to leave as original as I can. After talking to John I do intend on using the 4 speed Elan box and upgrading the drive train. I will obtain some spyder engine mounts and have a look at the engine position and fouling that it is likely to take place at the air tank area. I know that the spyder (baby) elan chassis that I have on my standard car has the tankl cut away to facilitate the room in this area. This is the bit I have not figured out yet. Early days, may be a problem. Are you on spyder for the Plus two Zetec.

thanks Mike

[rgh0]

Mike

A Zetec will be pushing the standard 4 speed elan box close to its limits if you use the Zetec torque to its max regularily. I reached the limits at around 170 hp to 180 bhp in my twin cam and have had to do the following mods.

2 key problems

1. Fatigue failure of gear teeth, typically third gear. This can be solved with a Quaiffe straight cut conversion but expensive and noisy in lower ratios unless you are racing in which case a great option. Alternatively just replace them when they fail but Lotus / Ford 2000E ratios now hard to come by.

2. Spinning of the laygear cluster shaft in the housing. Hard to solve as the side loads ( especially in straight cut gears) tend to free up the shaft press fit in the box casing. It then vibrates and chews out the slot that locates its key at the end and then it starts spinning ! I have been working with the Elan Factory to develop a mod with a tighter press fit and an extra locating pin in the end of the shaft, I will know if it works in 12 months or so.

Rohan

[miked]

Rohan,
I am not going above 160 BHP. I have an offer of two 40's webers for next to nothing from my brother. I understand that I can obtain around the 150 ish mark with these rather than the 45's (?600plus).

Thanks for the advice these are the sorts of things I need to know.

regards Mike

[lotuselanman]

Gidday Mike,
I am using a rebuilt Lotus chassis, no problem there that I can see.
Rohan is correct in his surmising that the gearbox could be the weak link, the 2000E was only made for 135 HP but driven in a civilsed manner there should not be a problem.
Hang in and keep us informed.
See ya, Les

[stevebroad]

Hi Mike

As you may have noticed, if you have read "Cosworth into Baby Elan", I am doing a similar conversion Fun, isn't it?

With regard to the propshaft, I was running 168bhp at the wheels 20 odd years ago with the original propshaft, a few sprints and many drag starts up at Santa Pod with no problems. Ripped the flywheel off the crank, wound up a solid driveshaft but prop survived. Sold the prop on eBay recently and there was no play in the U/Js.

Hang on in there, the result will be worth it once it is set up properly.

Steve

[miked]

Steve & Les
Thanks for reply. Will keep you informed. Work keeps getting in the way.
Les, what exactly are you doing with your car in terms of chassis/engine. Are you on a really hot twink.

Mike