SE front suspension renewal & brake upgrade

[Sparky]

@Doulou has foolishly given me his gorgeous SE for front bushes/balljoints/bearings/dampers (springs already new)  and, if it arrives in time, a PNM front brake upgrade.  He's also sprung (see what I did there?) for the SJ camber upgrade kit.  Quite a nice job really, as I can muller pretty much anything getting it off.  Dismantled O/S yesterday and was prepared for a fight, but it wasn't too bad.  Front lower bolt was something between 18mm and round, and the lower balljoint nut had to be cut off on the bench.

Might do N/S today if I can scrape off the permafrost.

 

[Sparky]

As anticipated, the nearside job is much nastier due to corrosion.  Again, the lower balljoint nut wasn't going to give up easily.  Don't know if it's common practice, but if necessary (and possible) I loosen the steering arm bolts and swing it out of the way, giving space for a socket so I can then get good purchase on it.  Of course, this also makes the top balljoint nut more accessible.

The aft nut was seized to the upper link, so I deployed the Milwaukee UB40.  No point wasting time on it!

The lower arm fwd bolt was highly reluctant to move, but eventually gave up.  Not so with the aft bolt, which is severely corroded and won't budge a millimetre.

So again the Milwaukee saw required deployment.  I first cut away some rubber so I could see to ensure I wasn't going to drift into the chassis.

Then I carefully cut through either side of the bush and the bolt to get the arm out of the way.

With the arm out of the way, I can now concentrate on each end of the bolt individually.  Neither will move yet, not even the head when I lean my 200lbs into a breaker bar.  I'll leave them to soak, but will probably resort to heat tomorrow.  Viel Spass!

Time to continue depletion of the gin mountain...

[eeyoreish]

Nice looking car in an unusual colour combo. Vulcan Grey?

I used to see a late Excel in the same colours when I had my Pacific Blue Excel and that always looked smart too.

[Chillidoggy]

Admit it - this whole thread is just so you can show everyone your Milwaukee saw.

[Sparky]

Did I mention my Milwaukee tools?

[fjmuurling]

Hi Sparky,

If you take of the hubs, can you let me know the thickness off the seal? The dimensions are 48 - 62 - ( 7 or 8 ) mm (should be printed on the seal)

I know what I took out of mine but I'm not sure it is the right thickness.

[Sparky]

1 hour ago, fjmuurling said:

Hi Sparky,

If you take of the hubs, can you let me know the thickness off the seal? The dimensions are 48 - 62 - ( 7 or 8 ) mm (should be printed on the seal)

I know what I took out of mine but I'm not sure it is the right thickness.

I have new bearings to fit; the supplied seals are 48/62/8.

[Rambo]

Well done Sparky. Free B and B if you come up and do my M100's. Oh aye, bring your Milwaukee. They'll be a good test for it 😉

[Sparky]

Getting that N/S aft bolt out was a sumbitch.  A long soak seemed to have little effect.  The threaded end drew out, slowly, with lots of heat, but the head end was ludicrously seized.  I expended every idea I had, and a large trade pack of expletives.  Eventually it came out, but it was pretty much glowing when it finally started to shift.  Also got bushes and balljoints out of the arms.  One was routine, the other was 'fun'.  Bunch of pics for Paul:

[drdoom]

Ahh, the lovely British sea air !!

[Chillidoggy]

I can't see any blood anywhere. You really must try harder next time.

[Sparky]

I'm hurting inside.

[skiing]

Wowzers - I am not sure you will be able to re-use all of those fastners... 

[Sparky]

Having to juggle this job with grandchild-care duties, so it's coming along sedately.

I've cobbled together a new ARB bush insertion tool from bits of an old skool bush tool, a bunch of snubber washers, and a bearing race, and I'm very, very happy with it!  I can install the bush in seconds using this tool and (did I mention it?) my evil Milwaukee impact driver - no press.  It does take a huge amount of torque before that oh-so-satisfying pop.

All the other stuff is now renewed on the lower arms, and the new upper kit has been prepared.  New dampers installed.  They measure slightly shorter than the originals at full extension; it'll be interesting to see where the car sits.  It's now all ready for righty-tighty, some time in the next 48 hours...

Time to renew my attack on the gin mountain...

[red vtec]

On 02/04/2022 at 16:45, eeyoreish said:

Nice looking car in an unusual colour combo. Vulcan Grey?

I used to see a late Excel in the same colours when I had my Pacific Blue Excel and that always looked smart too.

Its Steel Blue A59 my Turbo is same colour.

[Sparky]

Finally sorted the front suspension.  I had issues getting it to sit as low as Paul likes, even with the platforms wound all the way down.  Achieved the desired effect after removing the rubber isolators.  The rest is up to Northampton Motorsport.  The brake upgrade is on hold pending parts delivery.

 

[Bling]

Nice job Gary despite the cars resisting sometimes....as always 👍

[Sparky]

Nerdy saddo alert, contains lots of pics as I really enjoy fixing this stuff:  Paul had complained of difficult gearchange, so I had a look at it today before he picked up the car.

Three bolts of the master gearchange unit were loose, and one was missing.  The baulk block was damaged due to maladjustment, and the nylon baulk bush was destroyed due to incorrect stick height.  This all combined to make gear selection a chore.

Fortunattely I carry some rod stock for such eventualities.

It's a little wide, so first I turned it down to 10mm diameter.

Then drilled through, 3mm.

Then relieved with 6mm to accommodate the screw head.

Cleaned it up, cut to the appropriate length, then fitted to the stick.

A quick cleanup of the baulk block, then set the gearstick height and secure, and finally some adjustment at the translator, and gearchange is now sweeet.  So much fun!  And Paul's a happy bunny.

[rudolphwolven]

On 02/04/2022 at 17:45, eeyoreish said:

Nice looking car in an unusual colour combo. Vulcan Grey?

I used to see a late Excel in the same colours when I had my Pacific Blue Excel and that always looked smart too.

* * * * *

That Lotus color is "steel blue A59" and very rare indeed....

I had the same '90 Esprit Turbo SE in steel blue for 28 happy years.........traded it in last year (36,5 k mls) for a new 2021 Evora GT 410 Sport....the last available one in Holland......only 3x GT 410 Sport on the road in Holland. I am very happy with my Evora............a world of a difference with the Esprit.....however the shape of the Esprit is beautiful and timeless

Edited April 27, 2022 by rudolphwolven

[Mysterae]

Lovely colour that Steel Blue.

@Sparky, you got off lightly with that bolt 

I wasn't so lucky... had to call in a mobile welder to glue it back on!

[Sparky]

Must admit, when I was lamping it, I was sweating about causing exactly that!

[Sparky]

Finally, the icing on the cake.  Not quite there; bit of pipework to do.

[Lotus5509]

wow super nice. That is such a big difference. Does PNM's setup fit under a stock wheel? 

[igreenrover]

On 02/08/2022 at 00:45, Lotus5509 said:

wow super nice. That is such a big difference. Does PNM's setup fit under a stock wheel? 

I know from recent experience that the PNM kit does not fit the stock SE rears. PNM thought it did but they have now revised the web site description. Unfortunately having already fitted the kit I had to add in rear spacers to get the wheels on. Some pictures;