Lotus Elan

Trouble with Plus 2 boot remote release . . .

PostPost by: Sea Ranch » Wed Sep 20, 2017 7:22 am

Greetings,

Wondering if anyone else has had trouble setting up the Plus 2's remote boot release cable. Mine worked before disassembly. All parts are now cleaned, plated, greased, reinstalled. The mechanism seems perfect (or rather, as designed/built by Lotus). But when I install the cable, sheath and handle, I can pull all I want but cannot get the latch to release the plunger. If I pull on the cable sheath in the wheel well, the latch pops. If I detach the handle unit from the door jam and just pull on it (handle, cable, sheath), the latch pops. If I run a naked cable direct from the lever through the boot and into the wheel well and pull, the latch pops.

But I can get no love from installing the cable and handle, and pulling on the handle.All the parts seem to work properly with the boot open and observing the pull.

Are the bends in the cable/sheath making the pull action not firm enough? (Never a problem with bicycle cable/sheath).

I'm stymied at the moment. :? Any experiences, theory, wisdom appreciated. :mrgreen:

Regards,

Randy
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PostPost by: jono » Wed Sep 20, 2017 7:40 am

Randy,

Is it a solid single strand wire in the cable sheath?

I can't recall having a problem getting mine to work - it's a little stiff however but does work with a firm tug.

Jon
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PostPost by: jono » Wed Sep 20, 2017 7:43 am

...just a thought - is the boot plunger/spring adjusted too tight so that's it's 'grabbing' the latch and making the effort too high? you say it works with the boot open. Is it a new seal on the boot which is perhaps to 'plush' ?
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PostPost by: tonyr27 » Wed Sep 20, 2017 8:22 am

I had to centralise mine after I stripped and cleaned the mechanism. I also put a little silicone grease on the moving parts. The spacers can also cause it to run stiff if not aligned.

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PostPost by: gus » Fri Sep 22, 2017 9:27 pm

I am going to surmise that since grabbing the cable works, the mechanism at the boot is fine.

tighten the cable so that it is almost released as it sits, see if that works
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PostPost by: Sea Ranch » Sat Sep 23, 2017 4:52 am

Gentlemen,

I've had a too-busy week at work. But been reading your suggestions as they've come in. Appreciate them all.

Cable is standard (actually factory original) stranded, with a replaced sheath. I, too, thought of the extra upward pressure of the new gasket (though I'd had the mechanism working fine with the new gasket installed as I did body work and fitting of the boot lid). I backed out the plunger to make the lid fit lighter/higher, but the pull handle still could not pop the latch.

To make a long story short, I finally started playing with the location of the plunger (latch part attached to the boot lid). Eventually I crawled into the boot (shell has no interior or fuel tank) and loosen the the plunger attachment bolts, then relatched and allowed the plunger to naturally center itself in the lower latch part. The pull handle then worked fine. I tightened up the bolts carefully to lock the plunger in place, and she now works beautifully. A simple short tug on the handle and the latch pops every time.

Only problem now is the super tight fit of the boot onto the new gasket/seal, when I adjust the plunger height to bring the boot lid down flush with the top of the wings. Whoa. If it doesn't compress and ease up this tight fit, I will have to consider carefully sanding down the boot aperature flange in order to lower the gasket/seal and ease the closure of the boot lid. Though I am paranoid about too much adjustment as I desperately want a water-tight boot lid seal. Right now I appear to have that: I built up the flange during bodywork and evened it all out, carefully profiled it around the rear corners where it drops down, etc. and did lots of test fitting. I did a light test yesterday and it seems fully sealed.

Anyway, am pleased to get this working right again, and thankful once again for our great forum members!!! :mrgreen:

Sincere regards,

Randy
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PostPost by: KevJ+2 » Sat Sep 23, 2017 9:04 am

Randy, congrats in fixing the problem.
I had the same problem on final assembly but by then the tank and trim was in so it was much more fun :D
I drilled the access hole as described in the workshop manual but at that stage, like your's, it was seized. The only way I could gain access was to knock out the hinge pins (not so bad with new hinges). The plunger / spring adjustment is quite exact and by design, it seems that the bootlid has to come back up slightly after pushing down to 'lock', leaving a slight gap that can't be reduced.
Glad to read that you're progressing well.
All the best,

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PostPost by: jono » Sat Sep 23, 2017 2:08 pm

Randy,

I had to do exactly that - took a flap disc to the boot flange as all the body repairs and high build had made it high and I suspect the new seals are a bit plumper that the originals

Horibble thing to have do it but it worked and of course you will never see it.

Jon
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PostPost by: Sea Ranch » Sat Sep 23, 2017 4:31 pm

Thanks, Kev and Jono.

I am endeavoring to do things in the right order to make assembly and fitment go well. But last weekend, I screwed it up on two different areas in two different ways! :shock: But I have done the boot lid and bonnet right, at least :roll:

And I can see that reducing the flange height to relax the boot lid fit is in my future, too.

Regards to you folk over there. 17 C here today, so enjoying the fall season :mrgreen:

Randy
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