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E 906 return to the road

Differential

I had to make my mind up about the seals change in place, seals change on the bench or LSD. LSD won. I didn't start early on the job (read that as nearly midday) the exhaust and chassis strengthening bracket came off quite well. Most of the nuts were OK to undo, some a little bit tight. The only two that were pigs were the ones that secure from the top rear diff carrier to the subframe, they came off with the help of a power saw. It was a bit of a shock when the diff came out with nothing
andydclements

andydclements

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E 906 return to the road

A weekend of little progress

This weekend I spent the first half of Saturday helping Owen with his oil pipe, this time the correct one was supplied. Sunday I helped Simon with his TE engine, it is back together (despite me forgetting to take a clutch alignment tool so had to do it by eye) and back in the car although it's just placed in there and everything that connects it to the car is not yet in place. So, what did I do on the E906? I pulled the ignition system apart and found a couple of issues that may have contri
andydclements

andydclements

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469H mikeh's extreme makeover

update

Its been a while so here is whats been happening on 469H. Suspension parts were sandblasted and painted along with other misc. parts including gas tanks. I also coated the insides of them with a tank sealer that works well. I've started assembly on the body. Doors are assembled and installed on the body. Headlight pods are assembled and installed on body. Pedal box/brake booster and steering column installed. Wiring is re-routed throughout the body and tailights installed. Gas tanks instal
mikeh

mikeh

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Mark Jones Blog

Rolling Chassis - Complete

As the title....the gearchange is like a Mauser rifle bolt. [attachment=19835:DSC05937.JPG] [attachment=19836:DSC05935.JPG] [attachment=19837:DSC05928.JPG] [attachment=19838:DSC05921.JPG] [attachment=19841:DSC05915.JPG] [attachment=19839:DSC05938.JPG] [font=arial,helvetica,sans-serif][b][size=4][url="http://www.thelotusforums.com/forums/index.php/blog/15-mark-jones-blog/"][color=#0000FF]Esprit S1, 238G, Blog[/color][/url] [url="https://picasaweb.google.com/108292765998464008070/Lotu
markjonesx

markjonesx

1
E 906 return to the road

engine back together

Yesterday I helped Owen change an oil cooler pipe on his GT3, not an absolute success (pipe was too short despite coming from a Lotus specialist). Today I fitted the refurbished pump that I've got back having forgotten I'd left it with Terry, and after much wasted time I accepted I had to secure the PAS bracket to the pump before securing both to the car. Anyway, back on, need to re-time the ignition and set belt tension but the rain meant I didn't want to take the dissy cap off and get mo
andydclements

andydclements

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E 906 return to the road

More done- one damper on, water pump off

I had to get my hair cut this morning so it delayed the start a bit, with breakfast it was effectively 10:00. I started trying to remove the water pump with the bonnet on but very soon decided I'd need if off as it would save time overall. I gave up and removed the timing belt as well. I decided given the choice, struggle with two suborn bolts into cast ali that secure the steering pump bracket to the water pump or remove one bolt from the sump and do those two bolts using the bench vice, the
andydclements

andydclements

1
E 906 return to the road

A bit further back

Last night (having picked the car up from the tyres being fitted to the refurbished wheels) it was missing on one cylinder, I initially thought it must be incorrect choke, pulled in after 1/2 mile and found no 4 plug lead not on fully, put it on and set off again. No difference but I thought the plug could be so soaked with fuel it will not spark, maybe the warmth of the engine will dry it out and it will start to fire correctly. Nearly home and while decelerating for a roundabout I get a coupl
andydclements

andydclements

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E 906 return to the road

A bit further forward

I couldn't work out why the air horn wasn't working but assumed it was either poor electrical connection or trumpets corroded. After lots of searching I realised there was another cause I'd not considered. The air compressor wasn't fitted. I found anew one that I had and connected it up, still no sound so it appears the trumpets are also failed. It now just has a little diaphragm one until I can get round to fitting new trumpets and attaching the compressor. Daylight Running Lights, I've fitt
andydclements

andydclements

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E 906 return to the road

Two steps forward one step back

Took it for a short run Sunday and was told I have no reversing lights, having reversed it back into the drive. Didn't go far in test run as was low on fuel. Took it and filled up at Sainsbury's today, only took £35 to brim it (so that's circa 25l). Got in and the gauge was still reading empty- oh well one more job to sort. I did at least find the reversing light issue was simply corrosion on the lamp holders.
andydclements

andydclements

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E 906 return to the road

It's taxed

Waiting for tax disc to arrive so I can try it on the road. Today I worked on the carbs, balanced them to get air pressures aligned and it does seem to run a little better on tick-over and rev up nicely but the real test will be when it's on the road. I've replaced the otter valve (complete with ali tube) with one I ad in the store and the fans no longer come on as soon as the ignition does, they do however come on when it gets hot so that's a good sign. I've replaced the rusty header tank
andydclements

andydclements

3
E 906 return to the road

It failed

Not much to worry me. Headlight aim- I didn't check as I hadn't moved it. The issues identified late Saturday then Sunday morning, carb needle not stopping fuel from pump, well I think that's most of one of the issues. It failed on emissions, being too rich and I think excessive fuel height in the chamber would do that, I already had it planned in to do a re-build of the cars due to the issue I found Saturday. Advisory on one top ball joint, both will be replaced as I have them just in
andydclements

andydclements

2
E 906 return to the road

It's at the test centre

I took it there today so that I don't have to do that first thing tomorrow, I think the snow that's here today may be ice by then. Found another fault this morning. The rear carb that I found was allowing the fuel to continue flowing even after the floats should have cut it off, well it made it into the no 4 cylinder. It locked the engine. I'd tried to start the car and the engine turned over slightly then stopped dead so I tried charging the battery again, it didn't even move on the starter
andydclements

andydclements

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E 906 return to the road

MOT test booked

I've fitted new plugs, the correct spec ones not like those the person fitted to get it going and now it starts easily. While trying to sort out the starting (should have replaced the plugs to start with) I mucked the timing up but that's back to 10 degrees now and the idle is nice at 900rpm. I've pulled one of the fan motors apart, removed the flakes of magnet that were jamming it, cleaned up the inside, put back together and refitted it. The fans were running constantly with ignition on, I
andydclements

andydclements

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E 906 return to the road

Getting colder so I'm slowing down

Well, radio/ head unit in, but need to quickly pull it out and swap over two wires (I think), it's behaving as though power is cut when the ignition is turned off so I assume I have transposed permanent and switched positives. Found the wipers park as normal when on wipe only but when they are used because of wash function they seem to park part way up the screen. That could be a motor out job. Darn! Anyway, still need to Waxoyl parts of the underside before taking it out for its MOT and s
andydclements

andydclements

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Mark Jones Blog

Headlamp Motors

Before..... [attachment=19550:DSC04570.JPG] [attachment=19551:DSC04571.JPG] After..... [attachment=19552:DSC05708.JPG] [attachment=19553:DSC05709.JPG] Reference Data; [attachment=19556:Lucas Pod Motor Strip.pdf]
markjonesx

markjonesx

4
Mark Jones Blog

Gearbox Position (Important!)

When installing my gearbox, it threw up an interesting positional problem which I'll reference below. I have a very early S1, 238G (Jan '77), it seems that all of the S1 before approx 350G had slightly different features, and hence, go together away from what the manual says. The problem I had with the gearbox concerns its position in the car relative to the other components, most especially the engine mounts. The vertical aluminium uprights on the gearbox are slightly shorter (top hori
markjonesx

markjonesx

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E 906 return to the road

Side repeaters= less skin on hands

Cold outside today, but at least it was above freezing for a while. I fitted the little metal plate that acts as part of the throttle stop, only a few mins of work but it does signify the end of the carpet fitting task. The new side repeaters I ordered have not yet arrived, one set lost in post apparently, another set sent but the ones that arrived were the wrong type, they were sending another set but then realised their supplier had sent them the wrong type hence me getting the wrong type.
andydclements

andydclements

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E 906 return to the road

Rest of carpet in, well nearly, more trim in

The weather yesterday was nasty, cold and windy so I decided to get a hair cut and then not do much on the car. Today, it's wet, windy and cold but I did some more work on the car. Yesterday I wired up the replacement motor for the window. Instead of chopping and changing the existing loom which then becomes a memory test for me in the future or a puzzle for any future owner I went for plan C (A= fit 5 pin relays in place of 4 pin and swap wiring to suit, B= wire as per later cars) which was
andydclements

andydclements

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E 906 return to the road

Passenger side window lift motor FUBAR

Short day on car due to cold weather and my spine. Anyway, fitted the new rubber seal to the driver's side window and the glass now goes up and down all the way, it stuck approx 1/3 way down with old rubber seal. That concludes the planned work on that door (forgot to check mirror function) so trim is back on although I do plan to replace the speaker at some point. Passenger door, frame is worse than the other side was, I may be able to repair it as I did for the driver's side, I may hav
andydclements

andydclements

3
E 906 return to the road

Window frame, now more metal than powder

I spent most of the working day (short days, the more my spine gets cold / the more I do, the more the muscles tense up) forming and fitting repair sections to the window frame. I made two sections to encapsulate the H section below the door/glass line. Each has a flat section approx 18mm then a hairpin fold (gapped approx 1.5mm, then after 4mm a 90 degree bend and the reaming is a flat of approx 5mm. It had to have cut-outs where the bolt tubes go. They go together and then get welded on t
andydclements

andydclements

0
E 906 return to the road

Window frame = powder

Didn't want to do too much and aggravate my spine issue, nor jobs that would cause it to get cold/ strained. I've fitted a few more bits of carpet and trim. The rear floor carpets are now secured via clips, the passenger side front floor one is secured via clips. The passenger side over-mat has been trimmed with a saw and secured using special clips (VW ones). Then it's onto the windows, passenger side didn't move but the driver's side did a bit. I tried lubricating bits I could get to but
andydclements

andydclements

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