Lotus Elan

Elan S4 Window Frame Cable Pulley Posts

PostPost by: RAJ2628 » Thu Jan 13, 2022 3:53 pm

I have started the process of re-fitting the window glass to the frame. I fell at the first hurdle. The 4 plastic cable pulleys don't fit the welded/silver soldered in posts. The retaining clips fit the post clip groove but the posts are wasted away in places and I am not confident they will remain in place. I don't want to go through the pain of cable and window assembly then find out in a few months time that one or more of the 3 legged retaining circlips have pinged off.
Does anyone have a source for the (4 off per door) cable pulley posts.
Alternatively does anyone have a drawing of the posts to manufacture new ones.
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PostPost by: Elan45 » Fri Jan 14, 2022 7:20 pm

They are just 1/2 inch brass rod, turned down to I believe .25 inch or .188 diameter. I'd think you could easily make new ones on your lathe, but I would think if there was wear anywhere, it would be the bore diameter of the pulley.

I just had a look at my pre-airflow coupe window frames this morning and the pullieys seem to be smaller OD than I remember on my later Elan. I meassured the coupe pulley at .75 inch OD and I remember my DHC as closer to an inch in OD. I thought I had some new pulleys here in Florida but haven't found them right now and I suppose I'll have to take a door apart on the DHC to check.

I suppose the pulleys on the coupe might have shrunk while it was in storage for all those many years. The cables are certainly loose.

Roger
'67 Elan S3 SS DHC
'67 Elan FHC pre-airflow
'67 Elan S3 SE upgrade to 26R by Original owner
'58 Eleven S2 (ex-works)
'62 20/22 FJ (ex-Yamura)
'70 Elan +2S RHD
'61 20 FJ project
'76 Modus M1 F3
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PostPost by: RAJ2628 » Sat Jan 15, 2022 12:52 pm

Hi Roger, thanks for your reply. I filed the tops of all 4 posts on one frame. They looked to be made from steel. A magnet picked up the filingst to confirm. There has been some suggestion through converstions rhat the new pulleys are slightly different to the originals. (The new design covers the post circlip groove.) I'll have to measure the pulleys and re-draw the post to get the groove in the correct position.
I'll keep you posted.
RAJ2628
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PostPost by: Craven » Sat Jan 15, 2022 1:51 pm

Maybe of some help, but there are several sizes of pulleys.
w2.jpg and
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