Lotus Elan

RSM949G 1969 S4SE FHC Mech refurbishment

PostPost by: Elanintheforest » Sun Feb 09, 2020 10:04 pm

Mine was the same Pete as it hadn't been moved for the best part of 40 years, but a bit of heat on the ally cover soon scared it loose!
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PostPost by: elansprint71 » Mon Feb 10, 2020 11:20 am

Mark....

Tried the blow-lamp... no good! I'd already worked my way through from a correct-sized socket with a long bar, Vice-grips, Footprint "dogs" … etc! Finished up grinding two flats on the remains of the plug/flange, using heat with 10" Bahco spanner with 18" scaffolding tube over it and a bloody big wooden mallet!

Had that not worked Plan D would have been to completely remove the remaining brass "head" and carefully drill out the centre until there was literally just the brass threads left, the unpick them out of the ally thread. Tricky stuff and, of course, it would mean dismantling the diff again to remove and swarf which had got inside. That is the "engine stopped in the middle of the Atlantic scenario".

It looks like DPO used some sort of thread-locking fluid, there is grey powder in the threads and it isn't aluminium oxide.

Onwards...…. :twisted:
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PostPost by: Elanintheforest » Wed Feb 12, 2020 3:47 pm

I'm not sure which is worse Pete...trying to sort out the last owner's mess / seized up bits or trying to fit repro rubbish that doesn't fit!
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PostPost by: elansprint71 » Thu Feb 27, 2020 11:07 pm

I'm seriously wondering at what point it makes more sense just to remove the body to gain access to all the hardware below! :evil:
Having done a couple of "body-offs" over the years I really think that I might have been better advised to do a third! All I've really achieved so far (and I've still to wrestle one Miller drive back shaft into place) is to change the diff and fit new lower wishbones! Ahead of me lies pulling out the engine, swapping the gearbox, fitting new core-plugs (Christ, I hope the block isn't cracked) and all the other stuff you don't even think of.

Today's absolute bastard of a job was trying to get that peculiar domed nut, which retains the diff tie-rod, back onto the damaged thread of the bolt welded to the chassis. Why on earth did they do that? A nut either side would have sorted it. Actually, I know the answer- back in the factory the bolt for the wishbone was fitted the other way around and there was no need to grind off part of the head to get it past the welded-in tie-rod bolt. It took me ages to make the start of the thread good with a swiss file.

So, tomorrow... somehow I've got to get the three bolts through the inner drive-shaft "wings" into the aluminium adapter plate for the CV joint, without damaging the threads. Jacking up the suspension, to limit droop, gets one to the point where the car is lifting off the axle-stands under the body. :shock:

When I did all this on my Sprint, with the body off and a Spyder Chassis and RSC twin rear suspension, it was dead easy, everything fell into place....

:|
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PostPost by: Elanintheforest » Fri Feb 28, 2020 9:08 am

I'd use a spring compressor Pete. The rear springs are from a Biro originally so will compress very quickly, and once everything is lined up, even fitting a Rotoflex is a doddle...relatively speaking.

If doing a full mechanical refurb I would definitely take the body off....but it sound like you're at the point of no return now!

So easy to work on :D :D :D
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PostPost by: elansprint71 » Thu Apr 09, 2020 9:13 pm

Elanintheforest wrote:I'd use a spring compressor Pete. The rear springs are from a Biro originally so will compress very quickly, and once everything is lined up, even fitting a Rotoflex is a doddle...relatively speaking.

If doing a full mechanical refurb I would definitely take the body off....but it sound like you're at the point of no return now!

So easy to work on :D :D :D


Yes, too far gone! Diff now back in, have loosened gearbox mounting bolts, not much more than finger-tight! The problem with taking on a project car is that one has to check everything!
Next step is to remove engine and box, a four-handed job: I've lined up my next-door neighbour for this but we can't get within 2 metres of each other.... back to the gardening! Actually I'll remove all those bits and pieces like radiator, hoses and cables... at my convenience; this job is the exact opposite of how Team Lotus spanner-men used to operate. Stay at home, keep safe. :cry:
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