Esprit Turbo project car - part3 - the further continuation

[Lotusfab]

Steve, your correct would have been easy with the carbs off.  I may need to take it apart to test. Think the turbo may be different to the S1 at the fuel pressure on the Turbo is 4 psi. I would think the S1 is less.

Thanks for the offer Dave, I will see how I get on. From my research I believe the idle Jet and pump jets get the engine to about 3200 rpm and then the main jets take over. The pump jet nut controls the total quantity and therefore duration of the extra fuel burst. This is metered at the correct rate by the pump jets. It should be possible to get in the ball park by driving and adjusting the setting. If it stumbles before reaching main jet operation I know I need more total fuel, bigger pump jet stroke - tighten nut. If it bogs down as the pedal if floored there too much fuel so loosen the nut. Its already so much better after a bit of tweeking. I renewed the diaphrams  and they may not be identical to the originals and so requiring a different  nut position.

By the way Dave the S1 carbs you did are behaving perfectly. I spent about six months tweeking the tuning and it runs lovely. If I can get the Turbo the same I will be very happy. Once the Turbo is done I will overhaul the S1.. 

I will take the carbs off the Turbo and set them on a bench if necessary. Im trying to finish all the other bits before I get bogged down in the tuning and second fix tweeks! Its still got to go back to the paint shop for final finishing. Its looking fab now the under louvre area is matt black. The Turbo is a real bling car. Ive only been out a couple of times and each time people have commented on how awesome it looks. Funny, as where I live no one ever says anything! 

[LOTUSMAN33]

Happy days Fabian, the offer is there mate. 

She looks gorgeous now, you must get some shots of them together once the ski racks are done. You can’t beat a turbo with comps and Goodyear highlighting IMHO.

👍🏻👍🏻👍🏻👍🏻

[Lotusfab]

Tailgate louvres finished! Used silicon. Time will tell how it holds up. On the orginal car the lower ski racks werent rivited to the louvres. So neither will mine be. They may appear so in some later pics due to repairs.

 

[Andyww]

21 hours ago, 910Esprit said:

I found that there were significant inconsistencies between old and new diaphragms

Yes, SJ are supplying the wrong ones which doesnt help, if you get them from there, and also the ones for the HC and LC are different so I think other suppliers are also getting these wrong.

[Lotusfab]

I got all the carb parts from Eurocarb Rob there is very helpfulful. They cleaned them and replaced the air sealed bearings and adjusted the buterfles I did all the rest. Very easy it all just screws together.  Oh, and they also repaired the broken float mounts - excellent job. My only error not calibrating the pump jets. I probably will take it all apart and do just that, unless I can get it to work perfectly. A shame as everything else is great! I am especially pleased with my gearbox rebuild - Its very smooth and the clutch is also perfect. So many things could have gone wrong, but didnt. I wont be doing it again though!

Im now deep into the ski racks. The glass cloth Im using is too thin and has cause ripples in my styrofoam plugs. At least I can use isopon now the Epoxy layer is on. It will take a lot of work to get them to standard.Then its pVa release agent gel coat and four layers of fibreglass and polyester resin  to make the moulds. When these are done twenty coats of wax and then cast the final racks. The lower rack being split into two moulds. Should take about a week to make two moulds. Then I still have the other to do!

once these are done I have to make the aluminium ski holders that will sit underneath! 

[Lotusfab]

Quite pleased with this, the picture doesnt reflect the amount of work required to finish the louvres!

Ski racks

Have finally perfected a plug making technique. Its quite laborious but Im now down to the isopon stage of filling the epoxy covered styrofoam. The lower rack will need to be made from a split mould. I havnt made one of these moulds before so it should be fun!

[Lotusfab]

Wheel align

I have used the string method to set a rough front tracking. I have a laser tool but its tricky to use. Now its in the ball park I can drive safely. 

I am convinced all of the springs on my car are the wrong length, I have ordered a full set and will replace all of them. The ride height is still too high. I measured it at 190 mm from the lower rear chasis to the ground. It should be about 170 mm.

With these cars when they are in one piece the real work starts trying to perfect them! 

[Lotusfab]

Well why was my car sitting too high? I thinknthe previous owner must have been into Monster trucks! Heres his spring and the correct one! I now have to replace all of them!

Im going to beat this car!

[Andyww]

Mine was the same, as are many others. Previous owner had all 4 springs replaced and shocks by Morland Jones and they were all wrong.

 

[Fridge]

17 hours ago, Lotusfab said:

Wheel align

I have used the string method to set a rough front tracking. I have a laser tool but its tricky to use. Now its in the ball park I can drive safely. 

I am convinced all of the springs on my car are the wrong length, I have ordered a full set and will replace all of them. The ride height is still too high. I measured it at 190 mm from the lower rear chassis to the ground. It should be about 170 mm.

With these cars when they are in one piece the real work starts trying to perfect them! 

Yes, I used the string method to align the wheels on mine. Replicating the system illustrated in the S3/ET WSM which was sent to me by @RichardJGC 

Very fiddly, bordering on tedious, but definitely gets them into a reasonable position. Mine will go off for professional balancing and alignment shortly. Can't wait.

I'm not sure about the "real work begins", but you're right this stage is when the car comes alive. I'm REALLY enjoying driving mine.

Those springs though ..... wild. 

[Lotusfab]

I wish people who havnt got a clue wouldnt mess these cars up. Mr Chapman knew whatvhe was doing!

[Fridge]

1 minute ago, Lotusfab said:

I wish people who havnt got a clue wouldnt mess these cars up. Mr Chapman knew whatvhe was doing!

Yup!

[Lotusfab]

Got the second rear soring to do. Im really not looking forward to replacing the front springs! They should arrived today from S and J. Its mores gauling as I have already restored this bit!

[Lotusfab]

Well rear springs both replaced, 6 hrs! The front one have just arrived, Im having a days rest for those!

Car looks like its sitting correct at the rear now. The driveshafts are running at the correct angle.

[Lotusfab]

Front springs also replaced now. Theres and excellent guide on the Lotus Esprit World website on how to remove the springs. You split the upper wishbone, it makes it so much easier! 

Ive nearly finished the top RHS ski rack plug. Its taken hours and hours to sand and shape. Ive also started the smoothing of the lower rack plug. Im using Isopon P38 over the styrofoam which now has glass cloth and epoxy resin over it to stop the foam from melting! Laborious process to say the least. If the plugs are perfect there will be a lot less work required to the  moulds.

[Rolls]

📸 Please

[Lotusfab]

Havent really got any pics... heres a link to the suspension fitting guide...

http://www.lotusespritworld.com/EGuides/EMaintenance/Suspension_fitting.html

[Lotusfab]

The plugs so far, still farvfrom finished. They need further filling and smoothing. Then I have to make another top one because they are handed! Im not enjoying this bit. Im still a long way off getting working racks. But this is the worst bit to do. These will be fairings the load bearing part being metal and underneath these.

The car is now driving really well after my suspension work. I have compared the heights and now am factory correct. 

[drdoom]

Fabian, if I may hijack your journey for a moment - regarding interior trim, specifically the largest piece of material which covers the dash broadly. Does this also cover the scuttle right up to the base of the screen? I'm looking at my bolt-on dash finisher ( that which includes the glove box ) and suspect the method is to trim it on the bench leaving additional material sufficient to then glue over the scuttle once attached. Correct?

Steve 

[Lotusfab]

Hi Steve, I think I know what you are refering to.

The scuttle area is trimed with a piece of material or leather as above. It needs to bend over the top slightly to cover the area that can be seen if you dont block out the lower part of the front screen with tape or black screen colourant. It also extends to the lower area so the other bit of dash sits on top of the end. 

This part is trimmed on the bench. You need to replace the foam when you trim it to get the material to sit correctly. 

To be clear they are trimmed separately in the same material. As above.

[Lotusfab]

Looks like this when done.

Screen tape hides the transition area and makes it look neat. If your bonding the screen in dont put the sealant too far up the screen, it will squeeze al, over your newly trimmed scuttle area. It has to be low on the bottom edge.

You may recall I trimmed the scuttle area using new hide. I would not advise taking this leather off as it will rip. Then its a big job with a new hide to repair! 

[Lotusfab]

Second top plug almost there and the clamp top plug done. Should be making fiberglass versions soon....Shame is Ill be an expert then never do this again! On on the right is styrofoam covered in Epoxy resin. I did the left with glass cloth I dont think it need its so the right one will be covered in Isopon then smoothed. They are assymetric to fit the roof curve! Thats where everyone seems to have failed in the past. The skis sit horizontal. 

[Lotusfab]

Ok Plugs 90 per cent complete. Just have to mould the top part, sort out the tops of the racks then a final smooth. About 2 1/2 weeks on this! 

[Lotusfab]

The cars nearly sorted. I had an anoying smell of pertrol. I checked everything. As everything is new I couldnt understand it. Andy helped in that I thought the petrol caps were a bit loose. He pointed out a spring behind the seal presses it into place. A slight bend on the spring and ten minutes later both fitted much better. Hey presto, no fuel smell! 

Its really nice to drive. Cant believe its nearly sorted! Not  sure it will handle when the skis are on! 

[ANDYR]

Loving the look of the car, Fabian.

A controversial alternative to the fibreglass ski racks are these I made up in ploy carbonate and stainless steel.  skis held in place with rubber tree ties...

Racks drilled into car and held in place by bolting onto a large steel plate running along the underside of the top and bottom of the tailgate.  As tailgate shrinks when bolts are tightened, tube spacers are in place along the bolts to keep that gap a uniform size.

fotos show finished rear cradle and first fit to the my S3.

see you on the slopes...