Elan S4 rebuild - my story chapter 2

[seniorchristo]

Congratulations Guys!! Whopee!! Another successful rebuild almost complete! I can't wait to get over to see the results in person. You better be careful letting Drew drive. He might not let you sell it.
Later
Chris

[SF69Elan]

Really appreciate all the details of your rebuild that you've posted here - and what a great looking result!

[CBUEB1771]

The weather gods smiled upon us today. It was 60 degrees F by noon with sunny blue skies and no wind. It's the end of February and its almost unbelievable. This is convertible weather. Time to finish up the S4 !

I flew from Boston to Baltimore late on Sunday morning and looked down to see if you were working as we passed over Princeton. Unfortunately Elans are had to pick out from 34,000 feet but the weather did look great.

[Certified Lotus]

Chris, another month and we should go for a drive together

Thanks SF69Elan. I am am hopeful that my posts are an inspiration to all those that have "project cars" in their garage.

Russ, let me know next time your flying over, I'll arrange for a beacon so you can spot me

[Certified Lotus]

The rebuild list continues to get shorter, but as usual some missing part is needed to finish a task at hand.

I had ordered new locks for the doors and the boot as the keys didn't work and that would drive me nuts. Ray at R&D had what I needed in stock and shipped them straight away. I wasn't worried about replacing the boot locking handle, that seemed simple enough......and it was. Although I looked at a number of photos of cars to determine if the locked positon is up or down. I couldn't tell which was right so I picked locked up as it doesn't interfere with the license plate.

Original boot locking handle and lock

new boot handle and old comparison

I had also ordered a new rear view mirror from R&D as it was the proper type and the back was gold which will match the bumpers!

New rear view mirror

Drew pulled the head/valve cover while I was working on the locks to check the cam shaft to valve clearances. Everything was to spec.

Checking valve adjustment

He then replaced all the distributor to spark plug wires and coil wire with a new set (the old set was more than 15 years old).

Replacing distributor cap wires

New spark plug wires

I was deep into the replacement of door locks. Not much in the way of instructions in the Lotus shop manual or Bucklands book. A couple of posts on this website said it was a total pain to do......but I persevered. The removal of the locks themselves is interesting as there is alomost no space to put a wrench inside the door with the window installed. I came up with the brilliant idea of using a plumbers wrench to remove the locking nut on the back of the door lock and it worked perfectly!

Replacing door locks using plumping wrench

I was reassembling the door mechanisms and realized I was missing a door rod clip. Damn! one small little part prevents me from finishing the door card install. Another R&D order (sorry Ray, the parts orders are getting smaller and smaller).

The rebuilt generator hasn't come back from the shop, but that should be next week. Unfortunately my schedule is packed the next couple of weeks and so is Drew's so we are probably not working on the S4 again until April (at least that's what we put in our calendars). But that is OK, we are close to completion and it will be warm out in April for more test drives

[Certified Lotus]

Rebuilt generator and door clips. Now I just need some spare time!

[pharriso]

The rebuild list continues to get shorter, but as usual some missing part is needed to finish a task at hand.

I had ordered new locks for the doors and the boot as the keys didn't work and that would drive me nuts. Ray at R&D had what I needed in stock and shipped them straight away. I wasn't worried about replacing the boot locking handle, that seemed simple enough......and it was. Although I looked at a number of photos of cars to determine if the locked positon is up or down. I couldn't tell which was right so I picked locked up as it doesn't interfere with the license plate.

Well you proved Murphy's law... 50:50 & you were wrong... The long part of the lock handle should be down with the lock latched...

[Certified Lotus]

Figures. Where were you when I was installing the boot handle Phil? Another fix back on the list!

[Certified Lotus]

It's the details that count! Sourced the bracket that holds the pin to keep the glove box door closed. Will media blast and repaint.

[pharriso]

It's the details that count! Sourced the bracket that holds the pin to keep the glove box door closed. Will media blast and repaint.

image.jpeg

Where on earth did you find that??

[Certified Lotus]

I've found a source that seems to have almost everything I'm looking for. Amazing. Expensive but amazing.

[1owner69Elan]

The glove box latch on my S4 is much different (45/9182).

It says "Limread Tutch Latch". It's a spring loaded affair.

This is the original equipment, as I am the original owner.

Forgive me, but the latch you have looks a bit "home-made". But perhaps it is correct as your car is a bit earlier than mine.

If it works, great.

[pharriso]

IMG_5624.JPG

IMG_5623.JPG

The glove box latch on my S4 is much different (45/9182).

It says "Limread Tutch Latch". It's a spring loaded affair.

This is the original equipment, as I am the original owner.

Forgive me, but the latch you have looks a bit "home-made". But perhaps it is correct as your car is a bit earlier than mine.

If it works, great.

Glen & my cars are identical, maybe just federal late S4 & Sprint?

[Certified Lotus]

1owner69elan, interesting glove box catch you have on your car. I now have a sample of two types to reference. Can anyone else provide a photo of their glove box latch system? I'd like to know what is "typical" ?

[1owner69Elan]

I happened to be looking at my 1969 parts manual (obtained directly at the factory at the time I picked up my car)..

The "Tutch Latch", part no. 036 B 6150, is referenced for the S4 from car no 7895. So, in theory, as we know not everything is consistent with the Elan, the touch latch would be appropriate for your car no. 7941.

A quick google and it looks like these latches are still available new:

http://www.hafele.co.uk/shop/p/automati ... 12048/9610

This looks identical to the OEM one I have. Includes the catch that attaches to the door.

This a push touch type latch, no handle on the door. Push close, push open.