78070100S Progress

[drdoom]

Early days in the engine program.

[EXCEL V8]

Love the dry sump!  👍

Pete

[drdoom]

6 hours ago, EXCEL V8 said:

Love the dry sump!  👍

Pete

Yes, it's a thing of beauty in my eyes! The challenges are in creating the drives and ensuring no clash with chassis by way of engine movement. All that has been written on the chassis update from S1/S2 to Turbo/S3 refers to broadening the engine bay in order to accommodate a V-8 but it also afforded a useful bit of clearance in the vicinity of the D/S pump.

[drdoom]

Getting on diligently with the duly complex ( i.e. mad ) task of creating a viable serpentine drive for the engine, shall post pics once it's been assembled with permanent components. Otherwise, this being painting season, I've been going through the stray bits in need of touching up including the door and dash trims unique to the S1 and S2. Taking a tip from @Lou R I chose to prep and paint rather than seek a more authentic refinishing and could not be more pleased with the outcome. Verges on buffed AL while not as garish.

Cheers

[drdoom]

Some of the remaining dirty work now underway . . . .

 

[GTK]

that job is looming here too

[Fridge]

A great stage to be at.

That shouldn't take too long to bring it back like new.

[drdoom]

Copious quantities of WD-40, brushes and shop towels for now. Serious clean-up follows once the bellhousing and output shaft housings are separated from the 'box. Soon going to open the "crate" to see for the first time the gearbox purchased from @dsvitesse1 some time ago. Who needs Christmas when goodies like that just keep rolling in?

Cheers chaps

[Fridge]

I bet that cost a packet. Mine cost £1,000 to refurbish by a local transmission specialist, fitted with new pinion and output bearings and seals.

[drdoom]

18 hours ago, Fridge said:

I bet that cost a packet. Mine cost £1,000 to refurbish by a local transmission specialist, fitted with new pinion and output bearings and seals.

The most fearsome cost, one which I'd struggle to bear up against, would be to lose another dear friend before life on the road with Lotus is regained. Time is our more precious commodity after all. The push is on and though it will yet be some time before the Esprit is on the road I am working contentedly. No point in being the wealthiest knob in the cemetary.

[drdoom]

Undertaking to separate the bellhousing from the 'box at the moment. Might someone with experience in this advise whether my approach is likely to work. I've got it all up on the bench dangling from the engine hoist by the hanger castings, figuring it's enough to remove the 4 nuts within the bellhousing, the various bolts tying the main casing to the BH, and just those bolts tying the output shaft housings to the BH. Would this permit parting the BH from gearbox?

[910Esprit]

1.   Slightly slacken all nuts/bolts securing the bellhousing  (Not strictly necessary, but makes the drive shaft housings easier to pull away from the box, in the next step) 

2.  Remove all the bolts from the driveshaft housings - This will allow the driveshaft housings to be slid away from the box - Bear in mid at this stage that various spaces and the outer race of the bearings support the diff will want to fall on the floor!  So be prepared and make a note of their respective order.   

3 . Remove the 4 nuts from inside the bellhousing and remaining bolts securing the bellhousing, the bellhousing can now be lifted away from the box.  At this stage the diff is also free and can be removed    

Edited August 16 by 910Esprit

[drdoom]

Thanks, Steve. I took a slightly different approach as it was for the sole purpose of getting the bellhousing clear. Once the BH half of the output housing bolts were removed, plus all the others discussed, I was able to jolt the BH with a larger hammer and wood block then wiggle it along until it cleared the mating face of the output housings. So the axles and diff remained undisturbed and held by the remaining output housing bolts while I put the BH to use with my ongoing engine work. 

Harry's lovely gearbox, ring/pinion and assorted bits have been unveiled:

[910Esprit]

Steve - Did Harry provide the gearbox and you are attaching it to you existing bellhousing?   If so, my least favourite job, as I found the pre-load setting incredibly sensitive to the torque of the drive shaft housings etc.  Took me several (many!) iterations until I was absolutely happy with the balance of pre-load/backlash, but with a bit of attention to detail, you'll have no problems. 

[drdoom]

Harry provided the 'box, output axles with housings, input shaft, wheel studs and some collar or spacer thingy's I've yet to ID. The crownwheel and pinion, which are his bespoke items with uprated teeth reversed to suit the Lotus CW rotation, have been dabbed with yellow set-up paste for checking the tooth contact. Also to be provided by owner is the top cover with crossgate and selector levers. Your insights are appreciated thanks!

[JonSE]

Amazing progress!

Gearbox scares me more than the engine tbh, kudos on you for being able to go into this level of mechanical detail.

[dsvitesse1]

On 16/08/2024 at 21:14, drdoom said:

Harry provided the 'box, output axles with housings, input shaft, wheel studs and some collar or spacer thingy's I've yet to ID. The crownwheel and pinion, which are his bespoke items with uprated teeth reversed to suit the Lotus CW rotation, have been dabbed with yellow set-up paste for checking the tooth contact. Also to be provided by owner is the top cover with crossgate and selector levers. Your insights are appreciated thanks!

Hi, preload and BL all set by me. Only need to shim out the BH if needed.  Cheers, Harry

[drdoom]

Thanks so much, Harry. May I ask what factors would determine need to shim the BH?

[dsvitesse1]

Just now, drdoom said:

Thanks so much, Harry. May I ask what factors would determine need to shim the BH?

Hi, there are 3 options:

 

Width is the same, no need to shim.

Width BH  is a little more ( couple of tenths mm ) shim. Extra half paper gasket.

Width BH is al little less ( couple of tenths mm ) shim. Same as above.

Drill the 4 hole in BH 0.5 mm bigger. Easier to set the BH. You will  see in the work.

 

Cheers,

 

Harry