S1 Elan Rebuild - My Story

[Certified Lotus]

Thanks Craven. Was very careful about that pin. It's back in the rod!

[jk952]

Glen, remember to put thread tape on the bottom right bellhousing to trany bolt as drilled through into trany.
Incidentally I notice your subscript says 'adding lightness', wondered what items you're considering in that regard?
Jack

[Certified Lotus]

Jack, appreciate the reminder about the gearbox bolts. All sealed.

Adding lightness.......... this elan came with a full fuel race cell, huge fuel filter, very large holly electric fuel pump and pressure regulator. Plus associated clamps, brackets, blocks of wood and numerous bolts. All gone and replaced with an OEM style fuel tank and a small electric fuel pump. And then there were old parts that weren't being used but still bolted to the car. I have gone over every square inch of this car and if its not essential to driving and/or performance it's off. I have added a few more washers than Colin would probably allow, so I have some give back in weight

[Certified Lotus]

Dyno Day! Engine ran great and has a nice torque curve. Brought it home to install this weekend. More progress!

Dyno day

TC back in my garage

[oldchieft]

What was the story with the disappearing valve clearance?

Jon the Chief

[Certified Lotus]

Jon, all the top end parts were bought from a well know manufacturer and both the valve keeper and valve springs were not all to spec. It wasn't until they tore the head down a second time and measured everything that this was identified. All new parts ordered and the next set all spot on. I watch the engine rev on the dyno easily to 7500 RPM and it didn't miss a beat. No worries, I have no plans to run it to more that 6300 RPM.

This shop builds hundreds of race engines a year, primarily for formula car series. They have a huge amount of experience. The shop itself is an amazing place, and the work they do is top notch. I'm still drooling over all the equipment in the shop and the layout. I watched several people assembling engines and they are very methodical in their approach. The place was spotless and very organized. My kind of place!

[rgh0]

7500 rpm on a cast crank Your engine shop for all their skill and experience ( and failure to check components used on the build) has rocks in their head IMHO. I hope they guaranteed a rebuild if it blew on the dyno or fails in the next 24 months due to a crank crack they initiated.

Why test at 7500 if it will never be run there (and it never should)

Sorry if I am over the top and probably they know more than me but I have seen to many over revved twin cams fail :evil

sorry
Rohan
My avatar is there for a reason

[Certified Lotus]

Duly noted Rohan. I have had similar situations and worse.

Over the years I have learned to trust the individuals who are much more experienced than me. Guess I'll see what happens with this build over time. Road time will reveal all.

[rgh0]

mmmmm that piston sure got hot !!!
I hope is all pans out Ok

cheers
Rohan

[Certified Lotus]

Fuel starvation in high G corners causing engine to run lean did the piston melt on my track Exige S. I learned my lesson and the next build resolved all potential issues. Never had the problem again.

By the way, regarding my shops assembly, it's tough to tell if faulty materials were used in manufacturing. This wasn't about measuring, it was about the parts not handling the use near stated limits. Anyway, I'm pleased they delayed and rebuilt, shows the attention to detail and commitment to get it right.

[Certified Lotus]

As I'm getting close to putting the gear box and engine back in, it was time to make sure I had completed all the things that are easier to work on while I had plenty of room.

Finished routing the brake lines and attached to the 5 way connector. Interesting thing about the brake lines on this Elan. This car is left hand drive and I have it confirmed that is was delivered to the U.S. when completed in December 1963. But all the brake lines, hydraulic brake light switch and 5 way connector are on the right side. Plus the wiring loom connection for the brake light sensor is on the right side. The location of the 5 way requires a long run from the master cylinder.

Bolted the new drive shaft to the differential. Well, I didn't do it, Drew was here helping me and he spent over an hour trying to get the bolts to line up. These bolts have been shaved down on one side to fit the diff yoke curve. You had to have the drive shaft aligned just right to get all the bolts to fit. I'm not sure these are the originals and should probably replace them. I wonder if they are specialty bolts or I just need to grind a few heads appropriately?

The new engine needed the transfer of a number of fittings on the block for oil pressure line, block drain, heater hose, etc. from the old engine. Finishing up the details of the new engine was installing a new in box OEM Ford fan blade I had bought last year. Put a smile on my face to see that fan blade on the engine.

This weekend is the big next step. Install the gear box, engine and drill all the chassis holes. I might even get the cooling system installed. Then I expect another week to button up all the details and adjust the suspension and check for leaks. Getting close to finishing, but I know better than to rush.

5 way brake line connector

Gear box, engine ready for install

OEM ford fan blade

[rgh0]

Not sure exactly what drive shafts your fitting but you should not need to grind bolt to fit, so not sure whats going on without some photos. The diff output shafts in the earlier photos look like replacement high strength ones from TTR or similar which is good

cheers
Rohan

[Certified Lotus]

Rohan, I am using TTR drive train parts. The drive shaft is from them. I was wondering about the bolts that we used. They came off the car and it's clear that the bolt head will interfere with the curve of the yoke on the diff. Which is why they were ground down on one side.

Maybe I should just change to cap head bolts VS hex head bolts?

Drive shaft/diff yoke coupling

[rgh0]

Ok your talking about the tail shaft input to the diff from the photo not the diff output shafts. Is that a new component?

I would put the bolts in from the opposite direction

cheers
Rohan

[Certified Lotus]

Yes, tail shaft. The drive shaft is new TTR and the tail shaft input is original to the car. We tried reversing the bolts but the lock nuts won't fit flat on the curved side either without one side being shaved.

I'm going to switch to cap bolts. They will clear. Just need to find grade 8 with the proper shoulder/thread length.