Esprit Turbo project car - part3 - the further continuation

[Lotusfab]

Oil Pressure Test

I rebuilt the pump to as new standard and checked the pressure relief valve. I connected my Makita drill to the aux pulley on low speed setting. I packed the pump with graphogen and didn’t do anything else except -  put the turbo feed pipe into a measuring jug, block off the Oil pressure gauge hole, fill the oil filter with oil and screw it directly to the housing. I filled the engine with oil to its normal level. Then I started the stopwatch at the same time as running the drill.
After 14 secs oil was pouring out of the Turbo feed pipe. In another 16 seconds it pumped 600 ml of oil into the measuring jug! If I did this again and the pump didn’t perform like this I would rebuild the pump and run the test again. If it still didn't work I would expect an air leak at the pick up pipe. Happy days! 

I wish I had this info before and maybe I could have avoided a rebuild!  

Still, on the bright side I now have a far superior engine!

[Fridge]

I hope you clean that jug before handing it back to Rachel?! 😁

Confused by all the gearbox stuff. Wasn't all this done previously? Thread goes back weeks.

[Lotusfab]

Gearbox was done and was working really well. I drained it to take the engine out and found glitter type flakes on the sump plug, I took it to get it investigated, as I wanted to save time and get a second opinion and the backlash, Pinion height and preload double checked.I had a falling out with the professionals when they tried it on.
I then ended up getting back just bits and so had to rebuild it again. I bought another used gearbox and so was able to replace all of the selector shafts and other bits that although working were not In very good condition.  I then thought I might as well replace the output shaft and diff bearings as the costs have already gone out the window and this little extra is irrelevant. I now have a really good engine and gearbox.

[Barrykearley]

Be very aware that now the graphogen is out that pump - the oil will flow back over time if the pipe is left off the turbo. It is absolutely critical on any turbo car to check oil flow at the turbo oil supply lines to prove the oil pump is functional.

[Lotusfab]

Thanks Barry. I have been told by a very good authority if the pump is working correctly graphogen isn't needed. But I will be checking oil pressure again by cranking with the plugs out prior to start for sure!

[Barrykearley]

I can tell you with absolute no doubt or question if that turbo pipe isn’t immediately bolted onto a turbo and effectively sealed - it will allow the oil to drain back. Been there done that and proved it.

[Lotusfab]

Engine done! A few more gearbox bits then its engine back in! Everything balanced!

[ChrisJ]

I've just been looking at my tool roll and discovered I missed a tool out in my post with all the tools - Posted November 5, 2016

I've updated that posting with the new images. 

[Lotusfab]

Thanks, that seem a long time ago now!

[Lotusfab]

Gearbox finished! Just need to put it all back in the car. I am planing to put the engine and gearbox in separately, as I’m working on my own due Covid!  Thats how it came out, putting it all in together is really a two man job as the clearances are so limited. Should be about two days work to get it running, if there are no further problems and I can find all the parts.

[Lotusfab]

Just found this, pretty good if you don’t know these cars!

 

[Bibs]

 

[Lotusfab]

Plan B, the wife is going to help so tomorrow when the rain has stopped its going back in!

Once its back in I’ll feel like I’m almost there about five months  since it went bang! 

[910Esprit]

Think its the right option  (apart from one aspect you mention 😬).  

[Lotusfab]

Well its back in! I was working on a gravel drive on a slope. Less than ideal with plywood sheets over the drive. I had to use a Landrover to pull the crane and engine. After I started it was obvious I should have done the engine and gearbox separately. The extra weight on the plywood made it very difficult to control. But me and the wife struggled on and its back in.. It was easy last time as Andy was helping and I installed it from inside the garage on a flat surface.  I could not do that this time. Still we did it, but I managed to damage the bumper. Never mind I can fix it! So I have given up for the day with still a lot of work left.

 

[Lotusfab]

Thanks to Pete at PNM my wastegate is fully rebuilt with a brand new valve.it should arrive tomorrow. I seem to have lost the bottom plate on one engine mount! I have been working really hard and its just the exhaust system and Turbo left to do. A new Mocal oil cooler and thermostat to test. I have read the Lotus manual method of filling coolant. I plan to follow it and see if the coolant boils over is because of a faulty thermostat. 

The oil has drained out of the Turbo pipe and theres probably no graphogen in the pump. I suspect this won’t make any difference  this time to getting oil pressure, now the pump is as new. I plan to test this by cranking the engine with the spark plugs out and timing the oil pressure rise. I will report the result to help anyone else doing a rebuild.

I have been told if the engine gets through 100 miles without incident its probably a good build. So I plan to drive for over 100 miles in one go and test out the theory.

[Lotusfab]

I’ve been busy! Just need to test the gear change, fill up the fluids and do another oil pressure rest plugs out. Frustratingly I have installed everything except the turbo boost pipe. I am missing one olive! 
Pete at PNM has done an outstanding job on the wastegate. New valve is in and its a great fit,really smooth operation.

I tested the working pressure of the wastegate using a pressure.gauge and a compressor. It starts to move at 5.5 PSI and is fully open at 8.5. The only problem is when it starts to move is not when it begins to open as it is compressed in the wastegate. I thought of this after I fitted it. I now have to take it off again and test it in the old adapter ( bought a new one as valve seat was corroded). I will visually be able to see when the valve moves. 

[Lotusfab]

I’m very pleased with my heat shielding solution it is in perfect condition still and a massive improvement on the asbestos. . 

The new output shaft bearings have made a massive difference they are really smooth compared with the originals.

[Francisco Franco]

Looking good, a fantastic effort, lots of hours and money been put in, fingers crossed for the first hundred miles ( and the next 40,000) 🍻

[Lotusfab]

Thanks Phil. No expense spared this time. I plan to do some tests for leaks and then I am going to test it on a 100 trip. I just need to get an olive for the boost pipe. I am considering driving once around the M25 during a quiet period.

[drdoom]

Looking very much on track by this point, Fabian. Don't fret a shed-load on the boost control beyond what you have done so far, it won't grenade the engine in a flash if off target by a bit so long as the fuel and spark are close to correct. Just don't hammer away with the thing pinking to any degree whatsoever.

Cheers 

[Lotusfab]

Engine started. It takes 100 secs to crank and get oil pressure on a working turbo with no ignition, it only just registers. I cranked for 2 minutes and 30 sec before the oil pressure came up on my unprimed engine. Then I realised the battery was flat! If it had been charged the pressure might have risen sooner! I charged the battery over night, fitted the spark plugs and started the engine. It needs tuning but its running. Everything seems good, so out on the road later!

[Lotusfab]

I forgot how nice these cars are!

[LOTUSMAN33]

Better than it ever left the factory, great job now time to get some miles under your belt enjoying that beauty on the open road! 
The tuning is the fun bit and like you I like doing it myself 👍🏻
Dave  

[Lotusfab]

Thanks Dave. Nearly there on the tuning its within 3 mm but I want it spot on. Morgan carbtune, I had a lot of practice!   Slight oil leak form the rear cam cover on the inlet, easily fixed. I should have siliconed it as well as the rubber seal, as I did last time. . Its really smooth and pulls away so easily. Gears are really smooth and is the clutch.  No problem with coolant boiling out and trapped air? I just filled the expansion bottle, got it up to temp and then bled the radiator and topped up - fans working perfectly. No tipping on the nose needed. All the coolant filling issues I can say categorically are down to the thermostat not opening at the correct temperature. 
Idle is rock steady. All that remains now fix the cam cover leak and rack up the miles, happy days!👍😄