JPS Project

[Djs44]

9 hours ago, LOTUSMAN33 said:

They are coming up well, what are you using?

Dave  

I bought a small “Bissel” carpet cleaner and also used some Auto Glym upholstery foam . With the Bissel you can really see the dirt lifting 

[Djs44]

Disaster 

The " spare"  seat trim is quite different to the original ( and the row spec ) so I have a seat with a hole in it and nothing to repair it with . Any ideas ??

[Fridge]

If you want to retain the originality as much as possible you're looking at a localised repair. I understand that the material is available, though you have to be careful to obtain the correct style, as there are some copies out there that aren't correct. Then possibly ageing it to match. It looks like some professional intervention is required to me though.

[Djs44]

1 hour ago, Fridge said:

If you want to retain the originality as much as possible you're looking at a localised repair. I understand that the material is available, though you have to be careful to obtain the correct style, as there are some copies out there that aren't correct. Then possibly ageing it to match. It looks like some professional intervention is required to me though.

Any idea where to get the material - the stuff Roo has is ROW which is different . 

[v8vantage]

3 hours ago, Djs44 said:

Any idea where to get the material - the stuff Roo has is ROW which is different . 

That looks very similar to the material in my Federal car. Drop me your address and I'll mail a sample to you to compare.

[Djs44]

On 02/12/2020 at 15:32, v8vantage said:

That looks very similar to the material in my Federal car. Drop me your address and I'll mail a sample to you to compare.

Roo -I fear it is quite different to your trim 

 

 

Just now, Djs44 said:

Roo -I fear it is quite different to your trim 

 

 

 

Just now, Djs44 said:

Roo -I fear it is quite different to your trim 

 

 

 

 

[Djs44]

Sorry about the double posts ... 

 

 

Had the bodywork inspected over the weekend - car has had a new rear quarter rather badly attached . I had noticed the join line but not that the profile when viewing the car from the rear is slightly different side to side. One lower rear wishbone has a very slight bend which needs replacing . 

So the body will be away sometime early next year for a full sorting out and sunroof delete including the rear wing and fitting the new bonnet supplied with the car. There is also damage from incorrect jacking in one small area. 

Currently I only have the heater to strip and check and then I'm stuck as the chassis will be awaiting the engine and the I guess I can't do much to the body before it it painted ? If so the project will grind to a halt for 4-5 months. 

[v8vantage]

I see the difference now, it's difficult to photograph the material...you really need a close up to understand the two types used.

[Djs44]

With most parts now painted in POR 15 I tackled stripping the heater box last night. I want to replace the heater core to ensure no issues going forward . 

 

Some questions to those who have already trod this path . 

All the foam on the heater flaps has fallen to bits - what sort should I use to replace it ?

What about the rubber seals on the 2nd flap ?

Also the larger flap lever is broken and whilst i can possibly glue the 2 pieces back together , can you get new ones ?

I've noted writing on the side of the heater as shown , suggests it has been out before? 

Finally - repaint the outside in por 15 , leave the inside ( which is ok anyway) ??

 

[Fridge]

Hello Derek,

I've gone back to my original order list of materials for my S1 restoration and found these which were used for restoring the heater box to new condition. Hopefully they'll help. Unfortunately I cannot find the original links, as virtually all of the items were bought form eBay suppliers who look to have updated their descriptions etc. But they are low cost so I'm sure a quick delve into eBay using these descriptions will find the same or similar items. I did end up ordering some foam which was not used in the heater box refurb, but found a use months later on some other area of the car.

Here goes....

• ADHESIVE BACKED BLACK NEOPRENE SPONGE/FOAM RUBBER SHEET 2mm - 12mm THICK
• SILICONE SPONGE SHEET A4 SIZE 4MM THICK WHITE OR ANTHRACITE
• SILICONE RUBBER SHEET 200MM SQ 0.5,1,1.5,2,3,4,5,6,8 AND 10mm thick

I used some ordinary packing foam to surround the heater matrix, as anything else would be too substantial and hinder the re-riveting of the heater box. It just needs to be enough to hold the matrix securely. Most modern synthetics are far better than the materials available in the 1970s, so this will last as long, if not longer than the original.

The rivets I seem to have ordered were a combination, but you should be able to measure those that are removed to confirm, my order included the following:

• 4mm x 10mm Standard Open Copper/Steel Pop Rivets Pkt of 25
• 3.2mm, Pack Size: 50, Length: 10mm (possibly copper also)
• A4 Stainless Steel - Posi Pan Head Self Tapping Screws No.8 (4mm Diameter)

I chose to have my heater box gently media blasted, and powder coated, though originally it had just been painted. Mainly due to the potential humid environment that it could create inside. You can see this in the condition of many of these parts, even if no leaks from the matrix were present.  I also replaced the control wire retention clips (marked as Ford Cortina I seem to remember).

I have lots of detailed photos of this aspect of my restoration, which I did in the most of January and February 2017 whilst I was unable to work comfortably in the garage. However, I no longer have a subscription to this forum, so cannot post any more photos. Though I could email them if you so wish.

I covered the heater matrix rebuild in my restoration thread here https://www.thelotusforums.com/forums/topic/106541-giugiaro-esprit-s1-full-restoration/?page=2

It is important to replace the foams and rubber baffles on the heater flaps, as bizzarely this device was not fitted with an ON/OFF valve, so is reliant on good sealing to prevent heat escaping into the cabin. Note, I did not need to remove the flat rivets on the main flap, as I was able to slide the silicone rubber into the slot easily. Having cut strips to the correct length and shape of the originals.

What owner knows the repair history of their cars, unless bought from new, but I'd say that your heater box has been disconnected from the binnacle controls at some point, but perhaps nothing more. Hence the markings. As it is the one area on assembly that some special consideration is required.

Good luck with your progress. I found this was a very rewarding item to restore, and refit into the repainted body shell 6 months later.

 

Edited December 16, 2020 by Fridge

[Djs44]

Dave

Thanks for the info for the heater parts - I'm ordering a new matrix shortly and then I can paint and reassemble the unit. 

Got the steering rack back from Kiley and Clinton - really good job and nice people to deal with ( thanks again Dave ) . One control arm was replaced as it was banana shaped .... 

New u joint too so once I have new track rods ends this can go back on 

 

[Fridge]

Yes, they're good chaps.

Digbeth. My first taste of Brum back in the 1980's.

[Djs44]

Been there, done that ... ok not yet , but I have now got the T-Shirt

[Djs44]

Toot toot 

Got the horns  off today - only one more part to remove and the body is naked.

Although they haven't been used since 1993 , I thought I'd give them a go so wired them up to  a battery and .... promptly very nearly poo'd my pants. They are LOUD . 

A quick clean of the trumpets, just need to paint the steel parts and they are good to go. 

 

Can anyone suggest where I can get rear brake callipers at a reasonable price - I have none ?

Also the " crash pad " for the steering wheel and the plaque that sits under the radio ? 

 

 

[Fridge]

G-Esprit rear brake calipers are very rare, as are their internals. They were only shared by the Esprit and Lancia Gamma Coupé I believe.

PNM Engineering sell an alternative based on VAG/Audi A6 rear calipers I think.

[Djs44]

I’m after a picture of the electric window switch panel if possible - mine was missing so I have a new one and I’d like to see how the leather looks on it . 
thanks in advance 

 

[Rudi K]

Sorry about the quality of the photos. Taken in a dark garage! I can take some more if these do not help with your question.

[Djs44]

Perfect - thanks a lot Rudi - I can pop that bit down to the trimmers now 

[Djs44]

No progress on the build since last time ( apart from fitting the refurbished steering rack and new track rod ends)  but I decided to source/order  all the bits I need ( of course it won't be all the bits ...) 

4 pots front calipers and discs, rear PNM calipers and discs plus handbrake cables, all the fuel pipes including aeroquip carb hoses , all the alloy pipes and a full rubber hose set, all the brake pipes, coil overs and adjustable shocks, seat rails, master and slave clutch cylinders , a rear suspension link, chassis strut and all bushes, new rear bearings in the uprights, window switches, high torque starter, alloy rad and fans, gear linkage refurb bits and cross gait linkage, fuel pump and filters , a rear quarter glass, a pair of recon heater fans, oil cooler and pipes  and an alloy header tank. Oh and trailing arm bushes and bolts  and a rebuild for the brake master cylinder. Half shafts off getting new u/j s.

They will join the 2.5l engine, exhaust manifold , lightweight flywheel and clutch , mapped ignition and reconditioned carbs , 4 new headlights and surrounds etc , bonnet hinges and headlight hinges already in progress or procured. 

Leather is in progress . I'm trying hard to see if I can get the seat insert material remade but not getting very far at the moment . It isn't corduroy rather a woven product ( I think ) which I really can't see why can't be remade ( although it might require 1000 yards as a minimum batch I imagine 

Body is next in the queue for repaint ( hopefully start in a few months)  

I'm not keeping a spreadsheet as I fear I am already in " negative equity " lol .  

 

[Fridge]

I used to work near Aeroequip in Redditch after I graduated.

Not sure if they're still there.

My spreadsheet is not for the faint hearted. @Paul Coleman is a mere novice 😜

[Djs44]

Little progress on the car whilst I wait for engine , parts and body to go to paint . 

However I managed to find a gear knob on ebay that is in transit now - the seller said it had previously been on a JPS he owned . I've been in touch with him and he owned 3 cars over the years - one of which was mine in 2001 ! 

So maybe the original gear knob for the car  

The trim samples are due in 4 weeks for the seat inserts so that's coming on too . 

 

[v8vantage]

Does he remember which numbered cars he owned, helps keep track of them if they have not been seen for a while. Seem to be parts from a few "JPS" Commemorative cars turning up on EBay, wonder which cars they are from.

That gearknob on EBay was not an original Lotus one, it's a different shape to what was fitted to the Esprit.

[Djs44]

I like the fact that it may have been on my car at some point . The seller didn't know which cars he'd had but found  a record of my number plate in his files . 

As I didn't have a gear knob ,I'm happy with my purchase

[Djs44]

Finally managed to get the car re-registered in the UK . I had forgotten to tell  HMRC that I'd " imported " the car so my first DVLA attempt was rejected . Sorted the NOVA and have today received a v5 in my name with original number plate  . 

So welcome back to the UK   HLE 153T 

[Burg57]

Hello DJS, I am in a similar position to you as I'm currently restoring number 82! I'm probably a little further forward than you, my body is in primer awaiting top coat, engine is in the machine shop and the chassis is almost finished.