Lotus Elan

Front suspension overhaul

PostPost by: MarkDa » Thu May 31, 2018 9:14 am

Nice discs :D
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PostPost by: SENC » Tue Jul 24, 2018 1:20 am

Seeking your thoughts/guidance:

Got my rebuilt front konis back from TrueChoice. The only thing they couldnt replace were the bushings in the eye at the bottom of the dampers. Knowing that I ordered a pair sold for the original as I was getting caliper plate orings and a few other bits for the rebuild and figured I was paying shipping anyway so not much at risk. The measurements are essentially all correct on inspection, but with a couple key design differences, as you'll see in the pictures. The existing bushings have a steel outer casing (7/8" external diameter), the ones I ordered do not (7/8" external diameter). The steel core tube is 1.5" on both existing and new, but on the new the rubber is the full length whereas on the existing it is the width of the eye.

I can see some cracking on the existing bushings, but pushing on them there is still some resiliency so they aren't gone yet.

I haven't yet found proper replacements, has anyone else?

In the absence of proper replacements, would you leave the originals for now or use the new ones without the outer metal casing?

Thanks! Henry

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PostPost by: SENC » Sat Jul 28, 2018 1:27 pm

No luck, yet, on the shockeye bushes, so going to stick with existing for now. All set up for beginning the reassembly process, starting with getting the bellows on the steering rack. Looks like I might need one of those contortionist mechanics from the other thread - any tips to reinstall while the rack is on the car?

20180728_083332.jpg and


20180728_083601.jpg and
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PostPost by: SENC » Sat Jul 28, 2018 9:13 pm

I suspected getting the gaiters on the steering rack might take some trial and error, but had no idea I'd spend nearly a full day battling flimsy rubber in tight spaces before finally figuring out a simple solution that had them in place in moments and with ease. To save the next guy from the knots I earned beating my head against a wall, the trick was to create a collapsing funnel from a piece of a plastic milk jug. No cost and a couple minutes of time making one for each side, then the bellows slipped right on. I've added a few pictures below of the passenger side going on to make it clear.

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milk jug cone


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cone on steering rack


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slide gaiter over the cone, after feeding bottom string through


20180728_150437.jpg and
pull cone out


The only "trick" is set up the upper twine in a way that has enough friction to keep the cone together for insertion but that slides to assist in pulling the cone through the small end. Once the upper end of the gaiter is over the obstruction and where you want it, hold it in place with one hand and use the lower string to start the cone through the small end. Mole grips make easy working of pulling the plastic out.
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PostPost by: alan.barker » Sun Jul 29, 2018 2:12 pm

Nice one, well done.
Now try fitting new rubber Bushes in the Anti-roll Bar Drop Links :mrgreen:
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PostPost by: The Veg » Sun Jul 29, 2018 3:48 pm

Nice!

I went through new gaitors recently; wish I'd thought of that! I think I would-up loosening the rack so it could be moved to an easier position for fitting the gaitors.

Alan, that task is in my near future.
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PostPost by: SENC » Sun Jul 29, 2018 7:43 pm

Alan - I cheated and used poly pushes for the anti-roll bar. Not sure whether it was that or the freshly painted high gloss bar, but it went more smoothly than I expected after reading some of the threads here.

Had my son helping me and we made a lot more progess than i expected - or so I thought until, just after installing the dustshield and steering arm on the 1st side, I realized I somehow overlooked the trunnion seal. :oops: :(

20180729_152306.jpg and
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PostPost by: SENC » Fri Aug 10, 2018 9:13 pm

20180810_083231.jpg and


Reassembled and aligned and felt pretty good on a short, light ride. Still have to sort the water temp gauge, and given the blockage I was resolving when I broke the tube I don't want to push too hard until that is fixed. Also need to work on a battery tray solution - the old hold down screws are fully rusted to the bolt, so will need to cut them out and fashion something. But progress!
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PostPost by: SENC » Sun Aug 19, 2018 7:12 pm

I've used densyl tape to wrap and protect the adjustable component of the rear a-arms from corrosion. I've not used densyl tape before - for those of you who've done the same, did you overwrap or cover the densyl tape in any way to protect them from debris tearing it up?
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PostPost by: Bigbaldybloke » Sun Aug 19, 2018 7:29 pm

If wrapping something like that I would probably have used self amalgamating tape as it?s less likely to get stuff stuck to it, and I think more resistant to damage, but we all have our own preferences.
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