Lotus Elan

Honda S2000 engine and box

PostPost by: bigvalvehead » Fri Nov 09, 2012 1:06 pm

Hi Jon
Bought the flange from Ebay.com in USA and had it shipped.

Pipes are mandrel bent to avoid any distortion.
I have several friends who have installed these engines into Escorts and keeping the exhaust pipe lengths and diameters the same as stock is critical to maintaining the performance.

If fitted with throttle bodies they give a very reliable 290BHP !!!!!!!!!!

Cheers
Dave
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PostPost by: JonnyPlus2 » Fri Nov 09, 2012 9:17 pm

Hi Dave,

290 bhp ! That's staggering. From a production engine too. That motor in an Elan should be much nicer than in the S2000 which, let's face it, was a bit on the porky side.

I'm interested in the mandrel bends, do you have your own mandrel bender, did you have them made up ? Do tell all. Thanks.

Best,
Jon
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PostPost by: c42 » Sun Nov 11, 2012 9:49 am

Hi Jon

Try these guys, I have used them in the past - they are very helpful.

http://www.jetex.co.uk/website/custom_p ... =1.75+inch

Regards
John
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PostPost by: JonnyPlus2 » Thu Jan 03, 2013 10:56 am

Hi Dave,

How goes the 26H ? For some funny reason I am not that enthusiastic about entering my balmy (25 F) workshop, even while wearing my insulated winter weight boiler suit and fur lined boxers.

Happy New Year to All,
Jon
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PostPost by: bigvalvehead » Thu Jan 03, 2013 11:01 pm

Hi Jon
Not much progress due to new grandchild arriving in Nov and another due mid Jan.

I will be back in the workshop tomorrow and hope to finish the ex manifold in the next few days.

I bought the bends from ebay and the flange from Ebay.com

Cheers and a happy new year
Dave
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PostPost by: JonnyPlus2 » Fri Jan 04, 2013 3:33 pm

s2000 diff.JPG and
Hi Dave,

Congrats on the grandchildren !

BTW, the S2000 diff appears to have the crown wheel on the same side as the Elan diff so, unless I am missing something, you won't need an S2000 diff.

All the Best in the New Year,
Jon
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PostPost by: bigvalvehead » Fri Jan 04, 2013 4:58 pm

Hi Jon
The diff I am going to use is the Sierra Cosworth as I didn't realise there is a secondary ratio in the gearbox which lowers all the ratios.

With the 13 inch wheels I intend to use to keep the car looking period I will need the 3.62 ratio even at 9000rpm to get the best out of the car.

I'll work out the speeds later and post them
Cheers
Dave
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PostPost by: bigvalvehead » Sat Jan 26, 2013 10:27 pm

Gear calcs for the setup I will have

On the Turn Zero site you can pull up details of various cars then alter final drive ratio and tyre sizes.

Dave
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Turn Zero Technical Resources Gear Calculator.pdf
(133.33 KiB) Downloaded 781 times
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PostPost by: bigvalvehead » Wed Apr 10, 2013 8:36 pm

Hi All
The chassis is finally ready.

It will take the S2000 engine and modified gearbox and the gearstick is only 1/2 inch further back.

The Sierra Cosworth LSD is now fitted

Next step is to drop the shell on and sort out a route for the exhaust.

The A/C in the Japanese Shapecraft looks good and as I already have the ac pump I'm sorted.

I'll keep you posted on progress

Dave
Attachments
DSC02578.JPG and
DSC02576.JPG and
DSC02575.JPG and
DSC02574.JPG and
DSC02573.JPG and
DSC02572.JPG and
DSC02571.JPG and
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PostPost by: Bud English » Wed Apr 10, 2013 9:29 pm

Dave, Is that an optical illusion or will you end up with two different length half shafts?
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PostPost by: JonnyPlus2 » Wed Apr 10, 2013 9:35 pm

Hi Dave,
Very tidy looking job indeed ! Your work is an inspiration to this welder wannabe. Glad to see you're not afraid of a cold garage and that the 26H is coming along. If it ever warms up around here I shall pull out my MIG and start teaching myself to weld sheet metal.

BTW, I have no box for my car so I'm thinking either a T5 or an S2000 box. Does the front face of the bell housing end up any further forward than the standard Ford box and bell housing ? Thanks.

Best,
Jon
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PostPost by: bigvalvehead » Thu Apr 11, 2013 7:35 pm

Hi Bud/Jon

Not an illusion
the driveshafts will be slightly different lengths in order to get the propshaft flange central to the tunnel.

Not my welding Jon!!! I mocked up an old chassis and had this built from scratch.

I have to build up the chassis to rolling spec then drop in the engine and box before trial fitting the shell.

Probably will not collect chassis til week after next

Dave
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Turbocharged 26R clone (also in progress)
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PostPost by: JonnyPlus2 » Thu Apr 11, 2013 8:24 pm

Hi Dave,

I would have thought that buying a new chassis and having it modified would be cheaper and just as good. I'm wondering why you chose to have one made up.

Best,
Jon
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PostPost by: bigvalvehead » Fri Apr 12, 2013 6:52 am

Hi Jon
This is a new modified chassis in a way.

It was built by Gartrac who make the chassis in the UK.

They also used to fabricate all the parts for the works Escorts and still produce rally parts.

Cheers
Dave
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Elan DHC Sprint
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Turbocharged 26R clone (also in progress)
Evora 400 development car ex Lotus Factory
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PostPost by: bones » Tue Apr 16, 2013 6:10 pm

Hello, Looks like you have been doing a fantastic job on your car. I was wondering about your conversion with the S2000, I am wanting to do something similar but don't want to move the stick so far forward. Would I have to strip the box to get the selector rod out to shorten it? And just wondering about the flanges on the ends of the tube that you have shortened, have you kept them and joined them together or put a new tube in?
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