Lotus Elan

Front end overhaul

PostPost by: JonB » Tue Dec 05, 2017 7:06 pm

Well, the good news just keeps rolling in.

I was using a wire brush attachment on Mr Zurkon to remove rust from the brake caliper bracket and it slipped and took a load of skin off my left knuckle. What a Norbert, I should've been wearing welding gloves but I was just trying it out and got carried away. Now I have a bandaged up, stinging hand and am even less likely to be able to get the car ready for the Club meet.

:evil:

Fortunately I was able to get the wedding band off before it all swelled up, but it was pretty cringy trying to slide it over the damaged skin.

At least it is all done now. Phosphoric acid treatment for the surface rust (hey, what could go wrong?) followed by spray on primer then Hammerite and it's done. I'm not going to do the wishbones though I may slap some Hammerite on them for now.

Back to this loose trunnion. I tried to measure the movement but without a better rig it is very difficult. I got 0.8 - 1.1 mm on the OS trunnion, but the NS seems OK (sorry, had 'em the wrong way round before). I might try putting the old OS trunnion back on (with the bush and seal from the new one) if it fits better after degreasing. You never know... it's my turn for a bit of luck!
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PostPost by: The Veg » Wed Dec 06, 2017 3:14 am

JonB wrote:Oh god, this is not a "Dry Blackthorn day".

I have just dropped my digital micrometer in a khazi full of pissy water. Slipped out of my pocket while I was spending a penny.

:evil:


Jon, sorry to hear of your troubles. If it's any consolation, you've given me a good laugh looking up all those terms in your post that we yanks don't know. Thank you for this education. :mrgreen:

And truly sorry to hear of your injury. Heal well and heal quickly.
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"It just wouldn't be a complete day if I didn't forget something!" -Me
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PostPost by: JonB » Wed Dec 06, 2017 6:49 am

Dry Blackthorn is a cider made and sold in the U.K. They used that phrase in as a marketing slogan in the '80s I believe. The ads were memorable because they were quite funny.

Got my left hand bandaged up by the lovely Mrs JonB who rolled her eyes. It's not sore now, just inconvenient. Had to keep the bandage dry in the shower, alter the way I grip things, that sort of stuff.

Typically, my concern now is "how am I going to bolt up the steering joint now?" :lol:
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PostPost by: Bigbaldybloke » Wed Dec 06, 2017 9:23 pm

Mrs JonB sounds pretty useful, maybe her smaller hand could get in there to put the bolt in? I have to draft my Mrs B in occasionally when my fat fingers won?t fit, so she?d be in good company and it?s good training for the wives to know their way round things under the bonnet if they ever borrow the Lotus. I know mine coped quite well when she broke down in the plus 2 on the M1 in the middle of a section of road works. Mind you, I?ve never been allowed to forget it, my one year old daughter was strapped in the rear seat at the time and I was out of the country!
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PostPost by: JonB » Wed Dec 06, 2017 9:42 pm

Not a chance of that!
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PostPost by: The Veg » Thu Dec 07, 2017 2:47 am

Yep, saw some of those funny ads on YouTube.

Mrs. Veg has recently been introduced to helping me in the garage, and I think it won't be the last time. :D
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PostPost by: JonB » Sat Dec 09, 2017 5:52 pm

A quick update.

Got new uprights from CC, they look good. Trunnions don't fit properly, I suspect they are crap (not from CC).

So, I decided to make progress elsewhere. I used phosphoric acid to treat the rust on all the parts, sprayed zinc primer on the steering arms, calliper brackets and dust shields then Hammerited the lot (hubs too). Got to leave to set, then I can paint the other sides. Also Hammerited the ends of the lower wishbones. All looks satisfyingly shiny now. Of course it'll take forever to dry, because it's freezing out there.

A quick job would be to change the oil and filter, while it's up on stands. I know this should be done with the oil warm, so I tried to start her up. No luck, just a few coughs and a flat battery. Sigh. Back on charge!

I did look at removing the steering rack to change the rubber mount but it is a right git to get at. Anyway, it's tea time so I packed it in for tonight. House is so warm!
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PostPost by: JonB » Sun Dec 10, 2017 2:02 pm

Today in the South it was windy as hell. I had the Hammerite out to finish painting the various suspension bits. Did the upper wishbones and other side of all the other parts. Looking good, so thought I'd run the engine to prepare for an oil change. Garage doors open, nice through draught. Then CLANG! and the brake dust covers get picked up by a strong gust and blown across the garage.

Like buttered toast, they have to land on the part dried side. Grrrr. :evil: They will not look so good now! I give in... so now, who cares? You can't see them and any rustproofing is batter than none, right?
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PostPost by: JonB » Mon Dec 11, 2017 11:32 am

OK, progress.

  • Trunnions returned for refund, no quibbles. Good show!
  • Ordered another set from Canley this time and they are "Stanpart" according to the nice lady. Don't know if this is NOS or reproduction, hopefully the former!
  • Stub axles will be pressed out of the old uprights tonight or tomorrow
I'm thinking that I really should take the steering column out for a bit of a clean up. It's covered in greasy sludge, and I would like to see what condition the rack and pinion are in. Probably have not been greased in decades, and feel a but (not sure how to express this) "grumbly". No discernible free play, though!
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PostPost by: Bigbaldybloke » Mon Dec 11, 2017 11:59 am

If you do take the rack out give the gaiters a good check to see if they are perished and about to fail. Much easier to do with the rack out! Mine looked fine till I tugged at them then they split easily.
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PostPost by: MarkDa » Mon Dec 11, 2017 12:19 pm

Check before removal and save another delivery charge or buy anyway they're not pricey.
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PostPost by: JonB » Mon Dec 11, 2017 12:51 pm

I think they are OK. Some cracking in the inner folds. Will look again!
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PostPost by: JonB » Tue Dec 12, 2017 11:18 am

Oh dear. New Stanpart trunnions arrived, nearside still not fitting right. I can only wind it half way on before it locks!

new-trunnions.jpg and
Guess which is which...


:(
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PostPost by: JonB » Tue Dec 12, 2017 11:40 am

Another concern. Look closely at the kingpin thread on the upright in the foreground. There are machining marks evident, presumably caused by chattering as the thread is being cut. These are bad, aren't they? Leading to microfractures and eventual stress shearing of the kingpin - exactly the thing I am trying to avoid by fitting new uprights!
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PostPost by: MarkDa » Tue Dec 12, 2017 11:47 am

So that's a duff upright then!
A bit disappointing after all the hype they gave you.
An email with that picture should have a replacement and return carriage label in the post today though.
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