S1 Project car - part 2 - the continuation

[Lotusfab]

Sorry didnt mean clamps meant brackets. Renn has made two to support the center of the valance?

[Lotusfab]

Have almost finished the rear valance. Just replaced ignition with the powerspark. Seems to work quite well.

Have replaced the Servo valve with a new one. It has stopped the clicking. Has come to my attention the servo pipe is incorrect. Its very thinsonhave ordered the correct one from S and J. Will have to redo all the pipes so have ordered these also. It appears the header tank was not ckeaned before the reassembly so will clean this out while Im at it. Cant believe I still finding lots to do!!!

[Paul Coleman]

Looks like you have the later style rear valance. Not sure when they changed but Mr Bond's was different! The early ones had a more square corner around the exhaust...

Edited October 7, 2015 by Paul Coleman

[Lotusfab]

Mmmm see what you mean! Where do these bits go?

[Paul Coleman]

They're all activated with broom handles hahaha

[Lotusfab]

Well all The new pipes have arrrived from S and J. The servo pipe is thick walled and stamped to the correct spec. The pipe that connects to the top of the header tank popped off and the coolant pissed out again! Its the wrong pipe! Have the proper one so will fit this. There is a sludge in the header tank. Have decided to get a new header tank made as it will never be as good, trying to clean a forty year old header tank. 

Heres the rub - am hoping the sludge is old from the old header tank. The engine has been totally rebuilt and the radiator cleaned and refurbed. If the sludge didnt come from the header tank the headgasket might have failed. The old header is caked in old residue. This is the worst case senario. Plan to rebuild the cooling system, the water pump is new already. Then will retest. If the coolant spills out when the thermostat opens will get a block test kit and check for exhust gases in the coolant and check for an air blockage.  In this event I plan to rebuild the entire engine again. The head was done by PMN so no worries there. Think if I have to rebuild the engine may just as well start again from scratch and rebuild everything including the carbs. Realistically the trims not going to be ready until next year anyway!

[Lotusfab]

Plan B

Have got the correct inlet manifold coming from LOTUS BITS, There is no outlet so can just connect the cylinder outlet to the radiator pipe. Will take the carbs off at the same time and check the butterfly adjustment. Will then reassemble with a new header tank coming from Axminster Panels. They do header tanks and fuel tanks made to a very high spec. Will then Burp the system again and fingers crossed! If anyone is interested there is an excellent documentry of the Lotus factory in 1984 on youtube.

[Paul Coleman]

Is there anything left that's actually original hahaha You must have spent an absolute bloody fortune on this car as you seem to be re-restoring it!!

Paul.

[Lotusfab]

Have to be honest I would never have taken this on if I had known the cost and amount of work required! I never could have anticipated so many components would be either missing, useless or not original. I have little choice but to finish the project and ensure it is all done to the standard of all the other work. Looks like I will have to buy a new radiator too! So far its taken one year and five months of hard work. I had hoped the end was in sight but now who knows. Every single component on this car was useless, from the steering column to the fuel system, wiring and ignition. Its all now refurbed or brand new. Problem after problem.

I look at the doors that are now sorted and remember how many times I have taken them to pieces and put them back together. I thought It would be easy to run the engine as a new distributor was fitted only to find the distributor cant work on the Esprit as it has no internal oil seal. I then find the original was a Lumenition that now has no wiring or amplifier. So had to buy a recon points version from S and J and an exchange unit from Lotus bits. I get the engine running and find the coolant empties through the filler cap because its the wrong one. I then solve this to find the coolant empties through the  header tank top pipe because the pipe is the wrong one and not secured correctly and theres sludge in the header. The servo then ticks so I replace the valve and find the vacuum pipe is too thin. I then discover the inlet manifold and pipework is wrong.

These are only a snippet of all the problems! 

 I have the engine running smoothly at idle but Im still not happy with the engine temp and coolant. Have bought some temperature stickers as the engine should run at 82degrees. When the bits arrive will rebuild and retest. The radiator could be partially blocked even though it has been reconditioned t.his could be causing a pressure build up in the coolant as the engine is getting hotter than it should due limited radiator flow. 

Whatever project your doing cant imagine it could have been as much trouble as this. The only good thing recently is Ive managed to move the exhaust so the rear valance will fit. 

 

 

 

[Lotusfab]

Am going to see Sir Roger Moore this weekend so am hoping this will boost my enthusiasm.  

My next pictures will be of the car coming to pieces again!

[Lotusfab]

If anyone needs a header tank this is where I got it from, Andy has a unique talent for making parts of the highest quality.http://axminsterspecialistpanels.com

He can make the fuel tanks too.

Edited October 11, 2015 by Lotusfab

[Paul Coleman]

Lots

Of

Trouble

Usually

Serious

Have you ever actually driven one?

By the way if I were replacing the radiator I'd get an aluminium one. I have a reconditioned one with 3 Kenlowe fans on it and it struggles to keep it cool.

Edited October 11, 2015 by Paul Coleman

[Lotusfab]

That is the most acurate discription of this car!!! Anyone thinking of buying a project this really sums it all up. Have driven an S2.2 with a much better engine. Yep am thinking of the S and J ultimate rad. I have a recon radiator and its not very good.  A snip at £500! 

[jonroberts]

It's a labour of love Fabian. I've been struggling to diagnose a low RPM 'stumble' when hot and spent a fortune on complete new ignition, distributor (twice), HT leads, new coil (twice), NGK Iridium plugs to no avail. This weekend I borrowed a professional exhaust gas analyser and with this and a can of 'Ez-Start' found that I have air leaks on all the carburettor spindle bearings. I'm fairly certain this is the root cause so will now have to remove and strip both carbs (again) to replace them.  I guess I should have done it the first time around but they were not gritty or loose and the replacement is a difficult job, so I didn't remove them. My guess is the ultrasonic cleaner removed all the built up grease and gum that was keeping it sealed !  

Anyway, I think you are secretly loving this :-)

[Paul Coleman]

And I've got the same stumble as Jon but my bearings are all new My water pump is also leaking at the joint with the block and I can't stop it... poxy car hahahaha

Jon and I were going to come and see your car to find out which of ours breaks down first. I'm betting it will be mine!

[Paul Coleman]

Have driven an S2.2 with a much better engine.

It will be interesting to see if it lives up to your expectations - they always say you should never meet your heroes!! I reckon it's the fastest looking sports car a 1.8 Astra van can beat hahaha

[Lotusfab]

Hi Jon, well it certainly keeps me busy, some times its enjoyable then other times a nightmare! I bought some of those bearings and havnt fitted them yet. Euro Carb will refurb for a price £345 plus VAT and it includes the spindal bearings and all original parts. Its quite expensive to buy original parts kits not sure if its worth the extra for them to do it all. I Have read the link on replacing the bearings could be very easy or a nightmare! The guy at eurocarb does them all the time. My engine is sweet at idle but pressure seems to build in the coolant when the thermostat opens. Maybe this is normal? When I get the temp indicators on it I'll know if its cooling correctly. They stick on I got them from ebay. Will put on on the block and two on each side of the radiator. Maybe all Esprit s1s have these problems.

Ths is S and J rad. Very nice!

[Lotusfab]

Had my water pump leak a year ago and put a new pump on. It had been repaired with a bearing kit which didnt work properly. Is it true Lotus put Bars Leaks in these engines at the factory? Dont suppose Lotus would ever admit to it even if they did.

[jonroberts]

Make sure you don't have an air lock in the cooling system - its very easy to induce one when filling. I had to take off (from the same manifold connection you were asking about earlier) and fill the heater hose before I got enough water into the water pump for it to work properly. My symptoms were rapid engine temp raise after the thermostat opened and then lots of water ejecting under pressure from the header tank. The heater and the rad were not getting hot enough either which pointed to a water pump problem.  Some posts suggest raising the rear of the car when filling up with water to avoid air-locks. Are you sure this isn't your problem too ?

[Lotusfab]

At least Jon and you have MOTs!

Thanks Jon, thats exactly the syptoms I have. I had jacked the car up but maybe should have bled the rad and checked coolant at all hoses.

[jonroberts]

And I've got the same stumble as Jon but my bearings are all new

I'll lay money you have a small air leak somewhere. Use a can of 'Ez-Start' sprayed around all the carb joints/screws/misab plates/bearings/inlet manifold joints while the engine is running. Any change in engine speed indicates a vacuum leak as the fluid is drawn in and combusted. Be careful around the distributor though !

[Freemason]

 

. Have driven an S2.2 with a much better engine. ! 

A lot of people seem to be saying this. When it comes to rebuilding mine I'm thinking of upgrading to 2.2 spec.

[Lotusfab]

I would seriously consider the 2.2 if you can lay your hands on one.

[Paul Coleman]

I prefer originality personally and as long as you don't want to race a Nissan Leaf or Astra van it'll be more than powerful enough

You just have to accept the fact that you're going to get blown off by an Audi TT or the like but nobody will look twice at an Audi TT but an S1 will turn heads and it's fun to watch people just stand and stare as you drive by.

I'm restoring a 1965 FHC e-type and I'm willing to bet that the Esprit would draw a bigger crowd if you parked the two side by side.

Edited October 12, 2015 by Paul Coleman

[Paul Coleman]

Mind you, I wonder if they're thinking "Look at that knob in that old plastic car" hahaha

Edited October 12, 2015 by Paul Coleman