Lotus Elan

My Voigt 5-speed conversion

PostPost by: Mazzini » Wed Apr 08, 2020 3:56 pm

By the way, if you fit the speedo angle drive make sure it works and the cable is connected before you fit it, because it's impossible to get to once installed.
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PostPost by: steve lyle » Wed Apr 08, 2020 4:21 pm

To clarify the terms I am using:
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PostPost by: 1owner69Elan » Wed Apr 08, 2020 6:16 pm

It looks to me like the problem is the newer mounting plates ("cross member") that Alan sent only have the angle bend (return) on one side. The opposing side not being bent results in effectively a larger width and thus fouls the gearbox protrusion.

Look at Pharriso's version, angle bend on both edges. And Pharriso's, I believe, was a box that had been previously fitted and thus presumably is correct and works. Similar picture on another earlier post. by another member, shows the angle on both edges. Our new plates are just too wide, missing the angle bend.

I guess we have the choice of getting a new plate from Alan or grinding out enough on the plate to clear the protrusion. But, the original double angled plate would ostensibly be stronger and less prone to twist. I think Alan should provide the proper plate or give a reason why he is delivering these "cross members" in this way now.
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PostPost by: 1owner69Elan » Wed Apr 08, 2020 6:25 pm

Further comment on the crossmember plate not having the angle bend on both edges. It looks like the gauge (thickness) of the newer plates is much greater than the earlier ones. Thus, perhaps Alan didn't see the need to put the angle on both edges. IIRC, the plate gauge is much more substantial than the Lotus chassis that it bolts to.

IMG_5155.jpeg and
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PostPost by: pharriso » Wed Apr 08, 2020 8:23 pm

1owner69Elan wrote:Further comment on the crossmember plate not having the angle bend on both edges. It looks like the gauge (thickness) of the newer plates is much greater than the earlier ones. Thus, perhaps Alan didn't see the need to put the angle on both edges. ....

That I understand, but the front edge looks to be touching the bottom of the housing....
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PostPost by: 1owner69Elan » Wed Apr 08, 2020 8:48 pm

pharriso wrote:
1owner69Elan wrote:Further comment on the crossmember plate not having the angle bend on both edges. It looks like the gauge (thickness) of the newer plates is much greater than the earlier ones. Thus, perhaps Alan didn't see the need to put the angle on both edges. ....

That I understand, but the front edge looks to be touching the bottom of the housing....


Exactly. So "no go" at the moment. Either need to relieve the plate to not foul or get a "proper" plate from Alan.
I have emailed Alan asking him about this.

Unintended consequences by Alan? :

Strengthened the plate by using a thicker one, BUT now it doesn't fit because he omitted the front bend (flange).
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PostPost by: pharriso » Wed Apr 08, 2020 8:55 pm

1owner69Elan wrote:Exactly. So "no go" at the moment. Either need to relieve the plate to not foul or get a "proper" plate from Alan.
I have emailed Alan asking him about this.

Unintended consequences by Alan? :

Strengthened the plate by using a thicker one, BUT now it doesn't fit because he omitted the front bend (flange).


Do you have a local metal folding shop? Just need a plate bender to give that 90 degree bend.
-Or- put it in a large metal vice & whack whack as they say in Liverpool...
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PostPost by: steve lyle » Wed Apr 08, 2020 9:49 pm

pharriso wrote:Do you have a local metal folding shop? Just need a plate bender to give that 90 degree bend.
-Or- put it in a large metal vice & whack whack as they say in Liverpool...


Another option:
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PostPost by: steve lyle » Wed Apr 08, 2020 9:52 pm

1owner69Elan wrote:Alan already told me he forgot the gearshift plug and is mailing it to me. Not sure what that plug is but apparently goes in the hole at the end of tail piece “spine”.


Here's a shot of the installed plug:
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PostPost by: steve lyle » Wed Apr 08, 2020 9:53 pm

1owner69Elan wrote:
pharriso wrote:
1owner69Elan wrote:I have emailed Alan asking him about this.


Me too.
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1972 MGB Roadster @ https://www.mgexp.com/registry/1972-MG- ... 842G.4498/
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PostPost by: alan.barker » Thu Apr 09, 2020 4:39 am

Looks to me the blank was cut the same size as earlier thinner Plates and they forgot to reduce by the bending allowance of second Flange.
Just cut the excess away.
I had the same problem to fit a T9 Box on my TVR 3000S. I was supplied the Gearbox Plate through a TVR specialist. I just cut to have clearance no problem.
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PostPost by: 1owner69Elan » Thu Apr 09, 2020 5:15 pm

steve lyle wrote:
1owner69Elan wrote:Alan already told me he forgot the gearshift plug and is mailing it to me. Not sure what that plug is but apparently goes in the hole at the end of tail piece “spine”.


Here's a shot of the installed plug:


Was the retention screw and hole for it included on your gearbox? Mine is missing both the plug and no retention screw hole. I guess I can drill and tap a new one when the missing plug shows up.
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PostPost by: pharriso » Thu Apr 09, 2020 5:31 pm

That's different from mine, I appear to have a welch plug:
IMG_0110.jpg and
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PostPost by: steve lyle » Thu Apr 09, 2020 10:34 pm

1owner69Elan wrote:Was the retention screw and hole for it included on your gearbox? Mine is missing both the plug and no retention screw hole. I guess I can drill and tap a new one when the missing plug shows up.


Yes, the pic I took is as it was out of the box.
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PostPost by: 1owner69Elan » Thu Apr 09, 2020 11:14 pm

steve lyle wrote:
1owner69Elan wrote:Was the retention screw and hole for it included on your gearbox? Mine is missing both the plug and no retention screw hole. I guess I can drill and tap a new one when the missing plug shows up.


Yes, the pic I took is as it was out of the box.


Clearly dealing with a cottage industry. Not surprising, no real QC/QA, at least regarding some relatively minor things, that can be overcome:

1. Discrepancy on the mount crossmember dimension and/or bent edge. Fouls the gearbox.
2. No gear shift plug in my kit. Discovered by Alan before I got the gearbox and sent separately (not received yet)
3. No tapped hole or retention screw for the shift plug. Will have to create.
4. Gear lever finished rather poorly. Weld not cleaned up. Chipped paint. I’ll be redoing or replacing.

Again, nothing major, more annoyances. Hopefully, I don't encounter anything of import as things progress.
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