S1 Project car - part 2 - the continuation

[Paul Coleman]

I've played around with the mixture but haven't got an exhaust on it at present.

 

The worst jobs with the body on and interior fitted are probably...

1) changing the heater matrix

2) replacing the cross gate cable

3) replacing the aluminium tubes which run through the chassis

4) changing the water pump

5) changing the timing belt

 

I've done 2 of them so far so that means I'm still a 'Lotus virgin'

Edited July 4, 2015 by Paul Coleman

[Lotusfab]

I've only done two of these so far, but have done a lot of other unsavory things, such as a bulkhead rebuild! Three months of light pod fiberglassing! Glad Im getting closer to the finish. There's only so many Lotus problems you can fix before you start to loose it!

[Lotusfab]

If anyone would like to refurb their Kangol seat belt stalks, these press stickers are on ebay. http://www.ebay.co.uk/usr/bespokeroadsters?_trksid=p2057872.m2749.l2754

[Lotusfab]

Have built a jig to curve the bonnet al little and removed the steel strip for refurb. the plan is to place the bonnet edge in the wood and use shims to change the curve. Then rerivet the metal strip to hold the shape. Bonnet needs some slight repairs, nothing structural - just to achieve a better edge finish.

Its fun drilling the rivets out. They fall into the fiberglass recess. To remove had to tape a piece of tubing to a vacume and feed it through! Still just a few days of filling and rubbing down and should be ready for an Epoxy spray.

Steve Fulchers kindly started my dash, hoping to be ready for Friday. Then can put the binnacle back and all the other bits. Wonder what horrors lie in wait. Jons already told me about the heater cables!

[Lotusfab]

Does anyone know how the bonnet strut attatches to the bonnet? Have yoy got a picture please? Also how does the spare wheel fit in nthe front boot. It seems the hole for the wheel support is in the wrong place?

[V8-ESPRITS3]

my bonnet strut is attached with rivnuts? but not sure if thats how it should be? the bonnet hinges have bonded in bobbins and I would have thought the strut would be the same? but the S1 could be different than a S3? so not a lot of help!

[Lotusfab]

Thanks. The hinges on mine have plates, will have a look for some bobins.

[Lotusfab]

There are no rivnuts in the bonnet where the boot stay connects, could the rivnuts have been removed?

[V8-ESPRITS3]

well if they have been they would have left holes? any signs of them being filled?

[Lotusfab]

Yep there are two holes about 8 mm next to each other , a rivnut could fit in?

[V8-ESPRITS3]

yes thats how mine is fitted

[Lotusfab]

Thanks.

[Lotusfab]

Finally fitted the carpet studs to the front underlay, stainless screws from woolies.

[Freemason]

Is the S1 different to the S2 in this regard? My bonnet strut is not riveted in. There is a plate that goes behind a recess in the bonnet. The bolt you can see on the strut in the pic below screws straight into it. 

 

[Lotusfab]

Is the plate loose? If so how do you get it in thebcorrect position? Thanks.

[Freemason]

I think the plate or threads are fibreglassed into the bonnet. I'll check next time I'm with the car.

[Lotusfab]

Thanks.

[Lotusfab]

Had to do it, the doors are going back, couldn,t wait any longer too much stuff on the floor!

[Rolls]

Antonio. My stay is also screwed straight into the fibreglass.

[Lotusfab]

Have rebuilt the left door. Replaced the felt in the window channel with Woolies replacement, works very well. The glass is to stiff to be operated by the motor. The reason is the curvature of the frame. Can put shims in to get the resistance down, but this will take a while.

[Lotusfab]

Got the electric window working, but something very disturbing. There appears to be no microswitches or cuttoff when the motor has reached the emnd of its travel? This will cause a current overload and melted wires. Is this how they are? Has taken all day just toget this door done and now potentially have to re-design the window motor.

[Paul Coleman]

Yes that's how it was - no microswitches. Think it has some sort of clutch in it?

[jonroberts]

Window motors - add relays and separate power feeds to them. Two reasons: 1. Makes window motor switches last much longer. 2. Speeds up window operation due to less voltage loss.  I don't think there is a clutch in the motor at all.

[Lotusfab]

I've got the window resistance. Down to a minimum by spending a day adjsting the shims and new felt. The problem is when the motor reaches the end of its travel it stops and the load spikes causing a large currentbdrain and a lot of heat in the wires, until the switch is released. The relays would help as I could upgrade the wires. I am thinking of adding microswitches the cutbthe powervwhen the window reaches the end of its travel?

[Lotusfab]

Have ordrered all the bits to ugrade the windows. Will install microswitches as well. Once the car has an MOT am planing on installing a fire extinguisher system and a power cut relay operated from a switch in the cockpit. Simple Fire dril,

Ignition-OFF

Power cut - OFF

Fire Extinguisher - discharge

RUN