Lotus Elan

Elan +2 Non Spyder Zetec Conversion ( new photo's added )

PostPost by: RichP » Sun Nov 08, 2009 9:20 pm

Elan +2 Non Spyder Zetec Conversion, Comments Please.

I have spent the last few years perfecting the installation of a 2L Zetec into a standard Lotus galvanised chassis with the aim of keeping as much as original as possible. The drive train has been strengthened in the right places, output shafts, TTR Drive Shafts, lightened Flywheel and proper heavey duty clutch and Track Suspension etc. The Zetec engine bolts straight to the existing Gearbox and fits very well into the enine bay. The original 40 carbs are used and engine runs from special ECU, cooled by big rad and biggest fan possible, never comes close to getting too hot. Engine in standard specification, 155 - 160BHP.

The car performs very well indeed, acceleration is easily 6 seconds to 60, that car has done track days etc and handling is very good. Body fully repainted, interia first class and standard, also fitted new Minilite black and machined aluminum wheels with Yoko tyres. The car is fully sorted, reliable and in A1 condition.

I would like your comments regarding the cars value, where are we compared to a standard A1 +2 and a Spyder conversion ? any comments will be greatfully received.
Lotus Elan +2 Latest Photo's 0061.JPG and
Attachments
Lotus Elan Castlecombe 2.JPG and
lotus Elan Castlecoombe 1.jpg and
Elan +2 Zetec Installation 2.jpg and
Lotus Short Engine Install.jpg and
Lotus Latest Side 1.JPG and
Lotus Latest Zetec Engine Exhaust Side.JPG and
Last edited by RichP on Tue Nov 17, 2009 10:01 pm, edited 13 times in total.
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PostPost by: 1964 S1 » Mon Nov 09, 2009 1:41 am

The car's value, in my opinion, depends on where on earth you are. Is it RHD? It sounds like an exciting ride. I'd guess it's worth about what an original +2 in comparable (excellent) condition is worth, unless you're lucky enough to find a buyer willing to pay more for the added performance.
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PostPost by: GrUmPyBoDgEr » Mon Nov 09, 2009 8:47 am

Hi Rich,

It's good to see you on here.
There have been many questions posed in the past about fitting a Zetec into a standard Lotus Frame.
Your experience will be appreciated by many.
You've made a nice job of your project & I'm happy for you that the Car's running well.
What capacity Zetec did you use? I assume 1,8 Liter.
I'm sorry but I do not have the Market knowledge to be able to estimate the value for you.
You must be the Rich that came up to the Midlands to look at my Zetec S4 & bought my Yoko's; yes?

Cheers
John
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PostPost by: RichP » Mon Nov 09, 2009 9:36 am

Hi Eric and John,

Thank you both for your reply's,

Eric, the car is right hand drive and I am situated in the UK.

John,

It is good to hear from you, I have used a totally rebuilt standard specification 2.0L Zetec with the aim of keeping BHP to a sensible level, compared to driving the car with the original Lotus engine the transplant has transformed the performance of the car, it starts everytime hot or cold and does not have that puff of smoke on start up or any oil leaks, for me it has been a good project and a strong reliable car has evolved still being 80% original Lotus. You are correct it was me that came and saw your wonderful Zetec S4, for me it was your car that kicked this project off for.

Regards

Richard
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PostPost by: GrUmPyBoDgEr » Mon Nov 09, 2009 9:56 am

Richard,

thank you for your most flattering reply.
I guessed that you were one & the same.
Did you get the 40 DCOE Jetting information from Paul Dunnel or did you sort it yourself?
You share the same starting etc. experience as me; a thoroughly reliable Engine.
I have found that a Spark Plug change every 3 or 4 years is a good thing to do when running on Carbs rather than the originally intended Injection. That keeps the cold starting performance up to scratch.
Is the Oil Filter easily accessible in the Lotus Frame?
How did you manage the half Moon cut out, for the torsional vibration damper, in the vacuum Tank in a used (Petrol contaminated) Frame?

Cheers
John
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PostPost by: RichP » Mon Nov 09, 2009 10:22 am

Hi John,

The oil Filter is very easy to reach from underneath the car, regarding the half moon cut out in the front chassis member required to clear the front pulley of the engine, this was done carefully in a car body shop when the car and engine bay was repainted, great care was taken but no fuel contamination found.

Regards

Richard
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PostPost by: Spyder fan » Mon Nov 09, 2009 7:08 pm

Hi Rich,

For value I would say anywhere between ?14 - ?20k based on your Description, thats the ball park for a fresh and properly restored 'standard' +2, a Spyder zetec Factory car or a good non factory zetec build. Thats based on recent activity on Ebay and classified adverts. It doesn't seem to matter to the price whether you have every last gadget or upgrade fitted, a fresh and recent build seems to be what's wanted, any extras are a bonus and not counted it seems.

I have been under my Spyder zetec recently changing my starter motor (see zetec reliability thread) and I am still shocked at the size of the oil filter, its tiny to the point it hardly seems worth fitting and only just clears the steering column, there's absolutely no chance of fitting a sandwich type oil cooler takeoff. Mind you there's a very nicely made chassis member to clear the front pulley, its a work of art. My electrics are also a point of interest in that there are no relays used and some very neat blade fuses in the glove compartment, I have front & rear heated screens and HID Xenon headlights, this lot can draw 60amps if all on together, but it's bullet proof 2000's wiring with lots of safety and overload protection built in.

Do your Dellorto's give you any balancing problems and how does your ECU control things? Is it the 4 speed box you have fitted, is motorway cruising more relaxed that an LTC or just as fun & frantic?

Regards
Kindest regards

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PostPost by: RichP » Mon Nov 09, 2009 8:12 pm

Hi Alan,

Thank you for your informative reply, your +2 sounds very special, it would be good to possibly meet up at some time.

Yes the oil filter is very small, the carbs have been okay with the engine starting easily and running very smoothly without flat spots etc, although a final set up on a rolling road is soon planned. The ECU is a Raceline unit with Throttle Pot, I don't pretend to know how it works but it has done since the first start up. The Gearbox is a rebuilt orginal 4 speed unit, it is reving on the motorway but has great ratio's for the A roads and fun driving.

Regards

Rich
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PostPost by: Spyder fan » Mon Nov 09, 2009 8:43 pm

RichP wrote:Hi Alan,

The Gearbox is a rebuilt orginal 4 speed unit, it is reving on the motorway but has great ratio's for the A roads and fun driving.

Regards

Rich


Rich,
Fun is what these cars are all about, 5th is nice to have for long motorway journeys ( I do a few) but 2nd, 3rd & 4th are the most fun for A roads, I think the ratio's for 2nd 3rd and 4th are similar to a Lotus 4 speed box, 1st is quite short, but designed to not wear out the clutch in stop start motoring for the big old heavy Scorpio it was designed for, it feels a bit strange at first but easily got used to like most things and the zetec has a good torque spread so you don't have a dip in pickup between 1st & 2nd in normal driving. If I am in the mood I generally ignore the shift light in 1st (set at 6250 peak torque) and nudge just over 7000 sometimes hitting the soft rev limiter at 7500 which makes it nicely on cam for 2nd and the big grin that appears on face :wink:

I try to do all the main Lotus shows and will definitely be at the 3 counties next year as well as Castle Combe track day, hope to see you around.

Regards
Kindest regards

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PostPost by: gerrym » Mon Nov 09, 2009 10:34 pm

Alan, if you want to fit a full size oil filter (and stop carry over of debris due to high pressure drop), its possible to fit a Ford right angle filter adaptor. This also provides enough space for a cooler plate.

I've attached a link to Summit who sell these. I ordered one from the States no problems.

Regards

Gerry

http://www.summitracing.com/parts/FMS-M ... mage=large

of course, unlike the photo you would fit the filter facing down: ease of access from under the car plus it keeps it full of oil for start-ups.
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PostPost by: alaric » Tue Nov 10, 2009 12:48 am

Hi Rich. Great looking car. I'd love to know more about the conversion to zetec.

How much do you think the conversion would cost? I'd be interested in whether it's more cost effective than a rebuild on a twincam. I've put solid driveshafts on and have fitted a sierra t9 box, so the drivetrain should be up to the job. My twinc won't need a rebuild for some time, but when it does I'd seriously consider a conversion to a zetec instead of repairing the twinc, especially given the resale value of the twinc.

Sean.
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PostPost by: 1964 S1 » Tue Nov 10, 2009 4:00 am

I've got a stock federal 1969 +2 and I love this topic. I can only imagine what a whipped out Zetec +2 would drive like.
Lola GT versus Ford GT 40?
If I'm fortunate enough to come across a +2 basket case one day, (I'll never hack my original), I would zetec the heck out of it. Can anyone tell me about the Zetec motors in Ford Escorts and ZX2 models in the USA. Are the blocks compatable with the Elan bell housing?
Eric

ps; I'll stick with my value guess and agree with spyderfan... the location of these cars can have a surprising influence on their selling prices.
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PostPost by: gerrym » Tue Nov 10, 2009 1:33 pm

Sean re your thinking out load on the merits of replacing a worn out Twink with a Zetec as a cost saving measure, think it through!

In my opinion, a Zetec installation should be done for other reasons such as increased torque, ease of starting, robustness, ease of servicing or whatever "lights your fire".

As far as costs go, there are a multitude of small costs that pretty much apply to any engine swap but consider; would you be happy with the stock Ford induction and fuelling arrangements, a custom or Spyder manifold/header and exhaust system will be required, there are various compromises and/or costs with the various sumps that can be used, will you fabricate your own engine mounting brackets or use Spyders and what about the 105E rubber mounts (or TTR's race items), custom wiring looms etc etc.

Lastly, the days of getting cheap good condition Silvertop Zetec engines must be numbered. Then you might want to consider a rebuild (not cheap if you want to spec this properly) or fit a Blacktop which complicates the installation (but gets rid of those nasty hydraulic tappets)

Regards

Gerry
Last edited by gerrym on Tue Nov 10, 2009 5:52 pm, edited 1 time in total.
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PostPost by: GrUmPyBoDgEr » Tue Nov 10, 2009 3:00 pm

Hi,

I've attached a few Photos of alternative spin on Oil Filters that fit my Zetec S4 & a 90? Adapter that I have waiting to be tried at the next Oil Change.
The Mahle Filter is numbered OC11 & the larger diameter Mann Filter W85.
The Mann filter makes up for its shortness with its Diameter (As the Actress said to the Bishop) & it is easier to fit.
With the 90? Adapter it should be possible to fit the original Ford Zetec Filter, which is much longer than he pictured Mahle Filter.
These filters are standardised parts so most other suppliers will have identical ones, just check the Catalogue for equivalents.

I'm not yet certain if there will be sufficient space to fit the 90? Adapter or if I will be able to position (rotate) it nicely so that it will be accessible from above as the Alternator & Carbs close up a lot of the available space.
The Adapter pictured was a gift from Magnetti Marelli but I'm fairly certain that Mahle & MANN have similar parts available in Europe.
By the way, the sealing Ring between the Adapter & Block must be of very high quality material because it should be considered as a "fit for Life" component. The Seals for them are usually supplied in "Viton" whereas the spin on Filters normally have much lower quality NBR seals which get thrown out with every Filter change.

Cheers
John
Attachments
DSCN0841.JPG and
Zetec Oil Filters Mahle / MANN
DSCN0843.JPG and
Zetec Oil Filters Mahle / MANN
DSCN0844.JPG and
90? Filter Adapter
DSCN0845.JPG and
90? Filter Adapter
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PostPost by: elansprint » Wed Nov 11, 2009 4:27 pm

Very nice job
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