1986 S3 N/A Project

[Choppa]

Looking good Simon, bet you've pleased with a finish like that even before the mop and polish.

[slewthy]

Definitely pleased with the finish already. I was in an Audi and a Volvo dealership this week - their new car finishes aren't as good! Much more orange peel effect.

Tim, I know what you mean - the dismantling process is a very scary one (will I remember how it all fits/lose bits) and quite a depressing one - there is an exponential increase in the pieces that need attention as you go.

I'm now at the turn around stage - parts will soon start to go back on though I'm sure the box of 'wonder where this nut/washer/grommet came from' will grow rather quickly!

[silverfrost]

Simon,

The car looks fantastic chap, glad to see that you have finally got it back in one peice, As for the car its the putting it back together with all the the fresh paint that has always worried me as you always fret about scratching the paintwork, use plenty of covers and tape and bubble wrap sheet etc round the light pods etc when re fitting to avoid any accidents.

Good luck with the re build and look forward to the pictures and re build diary mate,

Regards danny

[slewthy]

You are right, Dan, scratches are a major bother now - never was before but now, even the lightest blemish would stand out like a sore.......well....a sore..thing.

Here are some pics of the other parts unwrapped. Has anyone ever built an Esprit in a front room before?

A note is that they were delivered in bubble wrap - great? non? No. As they guy who delivered them pointed out, even the bubbles in bubble wrap can mark soft paint, so all needed unwrapping ASAP. The fuel caps have bubble inprints on them!!! Nothing that the final polish wont sort but, BUG**R is nothing safe???

Anyway, pics of the car in temporary home before garage is secured. Cover is also temporary whilst I wait for my proper one. And, yes, the barn is a little grubby but at least the house martins are gone now.

Just imagine if I died tomorrow - what a barn find!!

Aaaaaanyway, first job is to lubricate those polybushes I've put in without lubricant!! An idea what lube I need to use? These are the split bushes from SJs. I'm sure they came with some stuff that looked like copper grease that I looked at, laughed at and ignored... I could just ring SJs but wondered if my current supplies would be correct.

[saggitarius]

That car looks really beautiful with the glossy black paintjob.

Congrats!

But a small information since you feel that the year you've worked with the project so far seems a long time and probably with a lot of frustration in the process:

In 1997 I started a full body off restoration project that I thought would take a year if I worked hard. But after a while I understood that I wouldn't manage in a year, so I updated the timeline to two full years. I also thought that I could enjoy the process more then, with the lack of pressure and stress. But it took until 2008 before I finally got the number plates back on, excactely 11 years after I started...

Then I had moved house twice, "enjoyed" a divorce, changed jobs twice and had to build a 50 square meter garage to work in - twice - because the new houses didn't have any accommodation for this hobby. I never gave up and always knew that I would make it. But eleven years did make the car a permanent part of my life. Cannot sell it - ever :-)

It was not a Lotus, but one of the competitors from the early days, a 1969 Marcos, that now lives in the garage with the S2 Esprit project. I have plans to finish her quicker than in eleven years, but who knows

Some of the process is described here: http://www.oye.no/Marcos.htm

So good luck with your Black Beauty.

Geir

Edited October 10, 2010 by saggitarius

[andydclements]

Lubing the polybushes?

The Lotus ones (I know you have SJ ones) use the lube to get them in more easily (tread as slightly less then impossible without the right tools) but the "lube dries an forms an adhesive to the steel.

If you've put the SJ ones in dry then I'd say leave them, the bushes are supposed to give some resistance to movement, centred around normal ride-height, lubing them will prevent that happening.

That car looks great with its new coat of paint.

[Wilf]

Interesting to see Geir has a 69 marcos - I had a 71 GT (steel chassis V4 but re-engined as a V6) a few years back. Wonderful car, amazing acceleration as it had the box ratios intended for the V4, but was consequently rather high revving at speed.

[slewthy]

OK, an update of sorts.

The weather has been a major pain but my new garage is now secure from the elements. Doors were a huge pain - expanding with the air moisture etc etc.

The concrete floor was extremely dusty, so that got sealed and treated with Ronseal diamond hard garage floor paint. The roof has also been dealt with to stop bits of old barn plaster falling. Holes all vented to prevent flying creatures getting in. Took for AGES!!!!

Rolled the car in for the first time today -

And then put on its new cover

I'm so happy! Ihave so much more room to work now, than in my last standard garage - I can easily walk infron and behind the car (albeit with no bumpers yet) and I have one bay to store parts and another to create my workshop. I am considering making a roll down poly sheet to protect the car from flying bits whilst I work - anyone ever done this?

So now, very soon, the rebuild can start.....

[cbclotus]

Looks fab. Well done. i think black looks great. Fantastic garage. Great looking S3. Mike

[GavinT]

Very nice. Looks like you've got lots of space. It's always fun seeing other people's man caves.

[silverfrost]

Very nice. Looks like you've got lots of space. It's always fun seeing other people's man caves.

Gavin , man caves, not heard that one before Simon, Great work on the garage it looks fab, Its nice whern you have a large clean area to work on the car, Every now and again i have a good clean up, very rare these days but when the place is tidy and all the tools are in the right draws, it makes working on the car not only faster but much more pleasurable

Good luck on finishing the car, any idea on a finish time.... Keep the pictures coming

Regards danny

[GavinT]

When I redid my garage, my wife wanted to hang some curtains in there NO NO NO NO. In the house you can do whatever you want. but the garage is all mine. Bless her, she was only trying to be nice.

[wayneb911]

Get simon how are you. Car is looking amazing I have to say. Well my life is back in order lol so watch this space cos i'l hopefully be back soon with a new esprit project

Wayne

[Bibs]

[silverfrost]

Get simon how are you. Car is looking amazing I have to say. Well my life is back in order lol so watch this space cos i'l hopefully be back soon with a new esprit project

Wayne

Wayne, Glad to see you back mate and even better looking for another esprit Hope all is well

Regards danny

[slewthy]

Wayne!!

You have made my day!

[slewthy]

So, for the first time in what seems like an age, I've done some Esprit work!

Just finished the construction of the workshop end of my garage into a useable space and got some shelving in.

painted the fuel tank top boards with fresh matt black. Not really required but felt like doing it. Brackets also treated for light rust.

My rebuild plan is coming together nicely on my spreadsheet - highly recommended if planning a big resto. Order of jobs can be changed and important things like 'tighten up the hub nuts' etc can be written in and hopefully not forgotten!

Also means I can 'work' on the car at times when I actually can't.

I've almost made up my mind to attempt a leather retrim myself. A job which will need to start soon- -the dashboard needs to be done before the steering rack goes back in.

Not looking forward to that pedal box though....

[slewthy]

Progress.

Fuel tanks in. With new closed cell foam, repainted boards and new vacuum reservoir fixing.

All breather pipes measured and ready to order. Diitto vacuum tubes

Pedal box in, it fits and preliminary tightening of bolts done.

OMG, I'm gonna end up scratching this new paint job. I'm going to have to stick the thin plastic sheet on and wear very soft clothes to stand an chance.

Anyway, I feel that the rebuild is starting. Really though, my garage is still very unorganised and I'm stretching over obstacles and I WILL fall with something heavy on the car soon.

Up until now, I was under the false impression that the dash running up to the screen (the screen finisher) was removable. Clearly not. Sooooo, to retrim this, a job high on the list in order to progress, do I need to take out the screen?

Both side chrome finishers are removed. What are my chances of removing intact if thats the way to go? Think I know the answer but I wondered if anyone has sucessfully removed a screen?

[mdw]

Up until now, I was under the false impression that the dash running up to the screen (the screen finisher) was removable. Clearly not. Sooooo, to retrim this, a job high on the list in order to progress, do I need to take out the screen?

Both side chrome finishers are removed. What are my chances of removing intact if thats the way to go? Think I know the answer but I wondered if anyone has sucessfully removed a screen?

If its the same as a stevens dash ( sounds like it) then you can recover it without the screen out. It just needs a lot of care to cut it correctly and tuck the final bit up to the screen. The passenger side screen vent was a nighmare to get on and off but it will go.

Edited January 26, 2011 by mdw

[lotus4s]

You might be able to do it with the screen in but IMHO it will never look 100%. I'm pretty sure the leather was put on in the factory before the screen and it does go under the glass a bit.

[mdw]

On my Stevens it looks llike it goes under the glass but you can see the screen adhesive at the bottom when the leather is removed so its not sandwiched between the fibreglass and the screen. Yes it would be easier without the screen in place but if you take your time you can do a perfect job.

[slewthy]

Yep. I'm sure this was done before screen insertion at Lotus but I think I would make a worse job of fitting a new screen correctly that replacing leather in situ. So it stays.

[USAndretti42]

I replaced the leather on my S2's dash with the windscreen in situ. It is awkward as the screen does get in the way of pushing the leather down into the little space between the glass and the dash and you have to be prepared to keep bashing your head against the screen as you try to see (Well you do if you are a thick as I am). The rough edge can be hidden by fitting a strip of windscreen tape which, I think, is used to hide the glue and goo that goes along the bottom of the screen.

I did once ask a well-known Lotus specialist about what was involved in replacing the screen and he said it will break when you try to remove it so leave it in.

BTW, taking the glovebox out helped with access to the passenger demist vent. Good luck!

[scottmgibb]

having watched two windscreens being replaced, it is - as you suggest - definitely not something you want to be doing...!

[slewthy]

No, I havnt been idle, just nothing relly exciting.

Ticking things off on my spreadsheet list gradually.

Body now reattached to chassis.Shims and spacers everywhere to prevent stressing the shell.

pedal box removed to do this and replaced - bugger!

Brake & clutch master cylinders in.

Front brake lines all finished.

Front heater tubes replaced. Nice new StST jubilee hose clips.

All vacuum tube routes examined and one detachment dealt with.

Heater control surfaces examined and found to be fine.

Lining up front scoop and radiator for fixing soon.

All rear fuel lines done, barring one banjo to fuel tank fitting - I've lost it!!!! Cant believe it, it doesnt seem to be a common size.

Jobs to do:-

Well, everything else, but next in line ..

refit and seal rear 'ears' and ducts -?add inline fan for cooling after engine stop?

restore quarterlight sills

radiator refit, scoop, spoiler

renew/repair front compartment loom & relays.

Refit heater motor

? upgrade engine startermotor to a powerlite unit.

I've gone for leather from Muirhead in Scotland and have chosen a plain matt black scheme. Since the leather is very expensive (but top drawer), I've got a guy to do this for me. I'll do the front dash myself, but the rest is up to him. I cant afford to screw it up!

Nothing to take pics of yet!