JPS Project

[LOTUSMAN33]

The engine looks good and as you say it has the baffled 2.2HC type sump like mine.

As David says with heat shielding, I’m running a SJ 4 branch with Volcanic wrap to reduce engine bay heat, mind yours is like a snakes wedding so that’ll be fun wrapping 😁.

 

[skiing]

I think mine was similar - It needs doing again really as it has started to break down. 

[Djs44]

Looks like I'll be busy during Easter . 

 

Any advice on fitting the box and engine ? 

[Fridge]

One way is to add the vertical gearbox mountings which contain the bushes, and carefully crane it in one piece into the chassis, whilst supporting the rear on a low trolley jack, and locating the top bushes into the cross-member.

[drdoom]

+1 on advice from @Fridge, the transaxle weight is considerable thus a compelling reason that those hangers be ready.

[TAR]

3 hours ago, Djs44 said:

Any advice on fitting the box and engine ? 

It goes in the boot  

[Barrykearley]

6 hours ago, Djs44 said:

Looks like I'll be busy during Easter . 

 

Any advice on fitting the box and engine ? 

Get a tractor

[Djs44]

I've only got a brand new combine harvester Barry ...

[Djs44]

Engine in .

A shortage of key nuts ( engine mounts ) meant I didn't get the engine in until today . 

I need to get the chassis rolling and I've forgotten to get the caliper mounting brackets cleaned up so I think I'll fit the discs and driveshafts and calipers can go on later . 

Next up are the brake and clutch pipes , gear linkage and exhaust and water pipes if they arrive. 

[LOTUSMAN33]

Good effort, looking smart 😎

Have you sealed up your gearbox end cover yet? I see you haven’t installed the silencer mount that’s all which means releasing the fastenings again if so.

 

[Djs44]

1 hour ago, LOTUSMAN33 said:

Good effort, looking smart 😎

Have you sealed up your gearbox end cover yet? I see you haven’t installed the silencer mount that’s all which means releasing the fastenings again if so.

 

Do you have a picture of how that mounts - that's one of the bits that was in the boxes ....

[LOTUSMAN33]

Hope these help?

 

 

[Djs44]

12 hours ago, LOTUSMAN33 said:

Hope these help?

 

 

Brilliant - thanks Dave 

[Djs44]

Snakes wedding .. test fit of exhaust . It is like the rubics cube ....

 

I need the mounting plate that the silencer fits to before I can secure in place 

how does one remove the driveshaft/disc connection piece - big hammer ?

[LOTUSMAN33]

That thing is a work of art!
Are you going to wrap it? You’ll definitely want a heat shield over that chassis bar as the paint will get cooked. Your chassis is in amazing condition as well.
Will the chassis brace bar still fit on this side with that exhaust?

Have you got any washers fitted between the radius arm and the mount?

This things going to fly, I see you have a crank sensor ring on the pulley so going injection with ECU route… 😎

Dave  

[Djs44]

40 minutes ago, LOTUSMAN33 said:

That thing is a work of art!
Are you going to wrap it? You’ll definitely want a heat shield over that chassis bar as the paint will get cooked. Your chassis is in amazing condition as well.
Will the chassis brace bar still fit on this side with that exhaust?

Have you got any washers fitted between the radius arm and the mount?

This things going to fly, I see you have a crank sensor ring on the pulley so going injection with ECU route… 😎

Dave  

Thanks for the feedback Dave 

It does look nice and now I know how to fit it ... I think I'll fit some heat shield material to the chassis and have some for the mount . 

I haven't put any washers in - I have some but I plan to get the geo done once it is ready . 

I didn't try the chassis brace yet and have removed the exhaust to trial fit the gear linkage - think I have a foul on the sump ( and then probably the exhaust 🤪) . I need to buy the heat silencer mount as mine is missing . 

I have mapped ignition but have kept the carbs . 240bhp/ton 😍

The disc inserts are out so I'll have a go at the brakes tomorrow . See what needs fettling ...  

@changes is ready for the chassis and is being very patient , which is appreciated . 

 

[LOTUSMAN33]

Cool sounds like you are all over it.

Normally the radius arms end up with 3-4 washers to get you in the ball park for the alignment.

Don’t forget you need the gearbox plate and the channel on thebS2 to mount the silencer 👍🏻
Dave will pick up any shortfalls when he gets the chassis as he’s an esprit expert.

Dave  

 

[Djs44]

Trial fit of the exhaust and chassis brace . 
Spent a good hour at Lotusbits with Mike and Dave getting all the bolts I’m missing .. 

hope ti fit the rear brakes and driveshafts shortly , then it’s the brake pipes and water hoses to fit and it should then be ready for the body . 

[drdoom]

That is one wild arrangement of primaries !!

[Stuart.W]

Hello Djs44, I'm very happy to have found your build thread, thank you for sharing.

This was my grandad’s car, he ordered it on the Lotus stand at the 1978 NEC motor show after he had fought his way through the 4 to 5 deep crowd of droolers. Leonard Charles Walker was 72 back then and passed away in October 2000.

I knew that I was unlikely to ever own the car since turning it down in February 2010. I last contacted Graham Capel exactly a year ago after asking about No. 44, did you get the original bill of sale with maybe 1 or 2 other documents from him?

“Thank you Graham,

I'm sorry I didn't get the original bill of sale to you before you sold it but I have it here and wanted to send it to the current owner. Do you know who has No.44 or is it best to put a post up on a Lotus forum? I also have a spare original running in letter that I assume came with the car from new, pics attached. Just let me know if that would be of use and I'll post it to you.

I hope it is restored and on the road, I'm extremely disappointed to be honest it's not mine but I knew I couldn't cope with something else back then. I remember getting picked up from school in it as a 6 year old 43 years ago, it's not something you forget.”

 

I have a photo of the original bill of sale but not the other documents, I understood it had been exported to New Zealand so I’m guessing that when imported back it then obtained a different vehicle registration. I won’t post up the original registration just in case you wanted to apply for it to keep with the car.

The scanned in photo is Len at Cliveden (year unknown), is not great quality but I do have a slide (dated May 79) of a much better photo to show the car off which I can send you once converted into a JPEG.

I would love to see it when finished if at all possible please.

 

All the very best with your build, happiness and enjoyment when used,

Stuart Charles Walker

[drdoom]

Lovely note from @Stuart.W. Further in regard to that exhaust manifold, is it possible to remove or replace with the body on chassis?

[skiing]

As far as I am aware, yes. It is on my S3 and was removed for a head rebuild post install… 

[Djs44]

Couple of questions 

1. The sliding bolts I have for the rear (PNM) brake calipers  are of 2 types - one type has a rubber sleeve on it , the other doesn't . I assume that they are used in pairs - i.e. one rubber and one plain one per caliper - does anyone know and if this is correct , which one goes at the top ?

 

2. I have new rear wheel bearings . When refitting the driveshafts , how tight are these in the bearings - do then need a bit of force to fit - how best to action ?

 

3. The cross gate linkage kit ( from SJ ) includes a bronze bush and a rubber sleeve - anyone have a pic of where these go ?? Also , is there a rubber grommet fitted where the cable goes through the chassis 

Lastly - should the gear change mechanism ( by that I mean the bits at the bottom of the gear lever ) be greased ??

  

 

Thanks for any advice . 

[LOTUSMAN33]

Yes one of each for the sliding bolts, I can’t remember which one was which though.

The sleeve goes in the pivot lever the cable attaches too if yours is worn. I think the rubber is for if use the modified kit on an original cable from memory to slide over the thin rod.

I do grease my gear mechanism when I build it up, the area is dry in the tunnel unless you flood the car so it doesn’t need plastering with grease.

Dave  

[910Esprit]

The rubber sleeved brake pin is the trailing pin.  Plain pin is leading