Lotus Elan

Slow re-birth of a Sprint

PostPost by: slowsprinter » Sat Aug 18, 2012 6:19 pm

Latest update

Home for the weekend and finally got my Elan body loaded into my van prior to its journey south to Option 1 to be worked on. I had been building a wooden frame which I have bolted the body to. This weekend I finally recruited visiting family to get it loaded into the van. Problem is my van contains some radar equipment and the only way my Elan fits is on its side! The frame was designed with this in mind. Should work :?

I'm not sure I am brave enough to bring the gleaming body back in the same way. I think I will have to hire a trailer and borrow a car with a towbar and bring it back. Probably on the same frame but mounted flat. We'll see!

Just remains for me to secure the Elan properly in the van with ratchet straps on the wooden frame. I plan to drive it down in a couple of weeks once I have finalised things with Option 1.

Stay tuned fellas. Photos updated.
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PostPost by: slowsprinter » Sat Aug 25, 2012 7:26 pm

All

Whilst waiting for an opportunity to take my Elan body down to Option 1, I decided to strip down my heater ready for a rebuild.

Having done that I need a bit of advice. I opened up the heater box and found a collection of pre-historic insects and leaves. I gave it a good clean. I noticed the foam strips on either side of the matrix and on the other side/both sides all disintegrated as soon as i touched them! I removed the matrix and spent some time straightening vanes then giving the core a good flush out.

My question is. When I come to re-assemble what sort of foam should I use to replace these strips. I suspect years of heat followed by years in a barn caused the disintegration. The new foam needs to stand up to the heat of the matrix yet be thin enough to fit around the vanes without damaging them and give a good seal to airflow. I hope you follow me! Not being familiar with different types of foam can you guys recommend something or do any of you have some experience of this job and can pass on some sage advice?

Regards
Ian
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PostPost by: ardee_selby » Sat Aug 25, 2012 7:53 pm

slowsprinter wrote: Not being familiar with different types of foam can you guys recommend something or do any of you have some experience of this job and can pass on some sage advice? Regards Ian


I used sponge strip very similar to that listed by Woolies. Can't remember where I got it from. Wasn't Woolies...Creech maybe?

Various sizes & thicknesses available: http://www.woolies-trim.co.uk/c-132-sa-strip.aspx

Cheers - Richard
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PostPost by: slowsprinter » Sat Aug 25, 2012 8:06 pm

Richard

Thanks for the prompt reply. Can you remember the thickness? My guess is about 12mm thick by 20mm wide. Thanks for the link it is a new site for me. Could be useful though!

Ian.
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PostPost by: ardee_selby » Sat Aug 25, 2012 8:23 pm

slowsprinter wrote:Richard

Thanks for the prompt reply. Can you remember the thickness? My guess is about 12mm thick by 20mm wide. Thanks for the link it is a new site for me. Could be useful though!

Ian.


Sorry Ian,

I can't remember exactly what thickness I used. Maybe trim the Woolies 13mm x 25mm to suit?

Cheers - Richard
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PostPost by: AHM » Sat Aug 25, 2012 8:41 pm

I'm using some of the foam that spray shopd use for masking - already sticky on one side and looked like the foam I took off.
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PostPost by: slowsprinter » Sun Sep 09, 2012 5:11 pm

Hi Gents

Major update. I have finally got my Elan body off to Option 1. I dropped it off on Friday 7th. For anyone that knows Frank at Option 1, he got married on Saturday. I wish him and Susan well.

Now I have to work out how I am going to pay him :shock:

8-12 weeks before I collect. Stay tuned!!

Ian
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PostPost by: slowsprinter » Mon Oct 01, 2012 10:23 am

Next Update

Heater re-build continues and next is a pedal re-furbish.

Fellas if you can look at my photos below you could answer a question for me? The de-mister vents I have, have an inlet diameter of 2 ins but the flexible plastic pipe is only 1.5 ins. This pipe fits onto the footwell vent with a jubilee type clip, ok. In other words all seems ok at this end. Am I missing an adapter or do I have anything that is wrong or not original?

Some previous owner had done a pretty rudimentary job with gaffer tape to make a join from pipe to de-mister. I would like to do a better job.

I had to replace the fan motor as it was extremely dirty and stiff to rotate. I put 12 volts on it and nothing happened. For the sake of time I sourced a replacement rather than trying to repair the motor. The resistor to give two speed fan operation measures out ok so was cleaned and put back in.

Option 1 have had my car body for 3 weeks now. Initial deposit paid!!

All for now
Ian.
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PostPost by: alan71 » Mon Oct 01, 2012 5:22 pm

I think you will find it was Lotus that did the rudimentary job with gaffer tape.

Alan
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PostPost by: elansprint » Mon Oct 01, 2012 6:00 pm

Ian you are a bit posh in Scotland we only have TomTom you have Radar in your van ? Sure you will be over the moon when the body comes back Frank's work is first class
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PostPost by: ardee_selby » Mon Oct 01, 2012 6:05 pm

slowsprinter wrote: The de-mister vents I have, have an inlet diameter of 2 ins but the flexible plastic pipe is only 1.5 ins. This pipe fits onto the footwell vent with a jubilee type clip, ok. In other words all seems ok at this end. Am I missing an adapter or do I have anything that is wrong or not original?


Would there not have been an adapter similar to that used on the +2? (I believe they both use 1.5" pipes)

Plus 2 vent.jpg
Plus 2 vent.jpg (41.7 KiB) Viewed 1134 times


Cheers - Richard
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PostPost by: slowsprinter » Wed Oct 03, 2012 3:23 am

Richard

That looks just the job. Do you know if anyone supplies these adapters? I know lotus sometimes cut a few corners but really did they gaffer tape heater pipe to vents?!!

Ian, since I got the elbow from McLaren F1 my radar van is a white elephant (silver elephant really) Mrs SS starting to apply some pressure now - says it blocks sunlight into the lounge. Can't see the problem myself - we live in North Scotland, we rarely see the sun! Anyone want a LHD sprinter van with a radar in the back?

Ian
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PostPost by: alexblack13 » Thu Oct 04, 2012 4:35 pm

Mine were taped in too Ian..

I cleaned the lot up, Painted the heater ass'y tested the motor carefully (If in doubt chuck it out is the rule). Reassembly was a doddle. The pipes were a good fit and everything works a treat. Apart from those wee eyeball flaps which will not stay where I put them. Driving along I find the shut themselves off.. Flamin aggravating is it.. :roll:

Alex 8)
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PostPost by: slowsprinter » Mon Nov 05, 2012 9:26 pm

Fellas

Got my heater re-furb finished. Fan works fine. Found the small circular vents in my collection of bits, I did not think I had any and I believe they are difficult to source being from a Rover P5. So that is a relief. Heater put to one side until I get the body onto the chassis.

I have half a rusty exhaust system (missing the silencer). I spent the weekend salvaging what I could. The intermediate pipe is mild steel and in reasonable shape so has been put to one side. The manifold to Y-pipe was very rusty but I have cleaned them up and I think they will be ok. I may paint with high temp paint. However, I ended up trashing the Y-piece and will need to replace. My question to you guys is this. I can get a new y-piece from Matty's, but can you confirm that I should have exhaust clamps on the three junctions with the y-piece (i.e. the two input junctions from the manifold and the output to the intermediate pipe. Should I use some exhaust jointing compound for the joins or some high temp silicone, or something else? Sorry for the stupid questions but I have no reference to work from other than a collection of bits! I want to install the down-pipes and y-piece onto my twincam prior to the body going on the chassis. I am replacing all studs, brass nuts and gaskets on the manifold too.

One more question on this installment. I am going to carry out an alternator conversion (put my original dynamo to one side) and indeed have ordered an alternator from Sue Miller. She pointed out that she does not have any alternator mounting brackets and asks if I can source one elsewhere. She asked me to ask on this forum if anyone knows a good source and if so she may buy one and try to get them remade somewhere and re-stock as they are difficult to obtain now. A quick look on Matty's and TTR's websites suggest that they have said brackets but the cost is almost as much as an alternator! Is that right? Anybody have any suggestions, please? I thought I read somewhere that the Ford Pinto engine has the same brackets.

Thanks once again, I always value the time taken by the forum in reading my saga and the help given.
Ian
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PostPost by: alexblack13 » Mon Nov 05, 2012 9:49 pm

Yes. You need clamps. Don't buy the common 'U' Bolt type as they are a pain. They put great neat indents into the pipes and make separating them huge 'fun' ....

Try these. Much neater and the local motorcycle shops sell them http://www.nccsupplies.com/HoseClamps.php?m=10

You can fabricate an Alternator mount from the dynamo mount. You will need a welder though. Got one? If not send the old mount and Alternator down, or drop it off when passing, and I will ruin it for you... :roll:

When do you get the body back?

Al ' ....
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