Lotus Elan and Lotus Elan Plus 2 Forums

So I have a rusted through RHS headlight vacuum pod and the MoT test is looming in 3 weeks. Nobody has any stock of pods and I’d prefer not to go electric lift.

What is the preferred method for keeping the lights up in the absence of the vacuum system? (Obviously I have the non- failsafe system in my car).

I’m guessing some sort of spring arrangement, but how exactly? I’d eat my hat if there isn’t somebody on here who hasn’t already “been there, done that”.

The pods might take a few months to come back in stock, so this might mean a summer of headlights up motoring but so be it.

Thanks in advance!

Steve
1967 S3 SE dhc

Alternatively:

https://www.ebay.co.uk/itm/203450328263 ... SwvSNgnRqk

Maybe some quickie fiberglass repair? Nothing pretty, just functionality.

Thanks Elanfan and gjz.

I think +2 pods are slightly different I believe, plus that pod on eBay looks even more rusty than mine , and good idea on the fibreglass repair I hadn’t thought of that.

Still looking for recommendations as to how to rig up a spring or bracket to keep the lights up.

TIA.

I've done grp repair in the past with a very good result. Tested in Bucket of water with a very little Air pressure. No Bubbles. While you're there remove the other one too. Clean complet on outside and cover everywhere Top and Bottom. Finish with Tissue for nice smooth finish. Coat of paint and nobody will know.
What have you got to loose, try it.
Alan

Bet its not as rusty as this one !!!!
But fibreglass does work......

Not done it but maybe use the stop screws or their bobbins.

Of course they keep the original fitting positions. It's the Domes that are glassed.
Alan

Just use a few sturdy tie wraps (zip ties) to pull the spring ends on each pod closer together.

+1 for GRP repair, it worked a treat for me and the pods are out of sight so only the obsessives need worry about the standard of the grp finish.

Snowy Elan that is simplicity itself, thank you.

I’ll try the GRP repair as others have suggested and if it’s unsuccessful I have the cable tie workaround for the MoT.

I have a plan! Thank you gentlemen.

UPDATE:

Turns out it's not the rusty hole in the top half of the pod which is the problem, it must be a split in the rubber diaphragm. Nothing t lose so I'm going t see if I can open it up and repair the rubber with a bicycle patch as others have reported on here before.

Bst
Steve

I made up this emergency headlamp lift aid from pencils and bits of perforated strip.

Well I didn’t like to say, but in view of your last post, I’m prepared to admit I have stuck bits of folded card into the gap on dark nights when I’ve been desperate to continue driving!

That was forty years ago when the lotus was my daily driver and I was young and foolish! (Wife says age hasn’t solved that one!)

I jammed the pod up then drilled a 1/4” hole through the side of the pod recess and the pod itself and bolted the pod into position. Drill two or three inches in front of the pod centre pivot bolt. Easy enough to do if you take the grille out and can’t be seen once you get a new vacuum actuator and remove the bolt. Might need to slide a washer or two on the bolt between the pod and housing to stop it pulling the pod to one side, depends on the gaps you have around the pod. The car was known as Nelson by its previous owner as only one headlamp went up and down!