Esprit Turbo project car - part3 - the further continuation

[Fridge]

Yes, my thoughts exactly.

Pity it's not mentioned in the workshop manual.

Like I said, it must have been a service update.

I've the additional washers, it'll just mean I need to remove the pin another time!

[Lotusfab]

Here's  better picture of the turbo suspension, its the same Idea with regard to washers, but better drawing!in between the rain I nearly have the engine ready to come out. I don't think I will be happy if the body is not taken off. So Inthink that's the plan. Will get stripping. Here's some pics. The enraging has got to some of the parts somwill have to do them again. Plus the previous work isn't really what I want.

I put the pictures on so people can see how the bits fit.

[Lotusfab]

Here's some of the trim, a big improvement on the S1.

The pictures show the fan wires and heater control cables.

Very difficult to remove the driveshafts, the Allen head screws were seized. WD40 and persistence and they all came off! Just a few rubber pipes and the engine can be removed.

[Paul Coleman]

There's a hardened washer on either side of the hub leg. So on your drawing the one between the damper and the hub is also hardened. The other hub leg has the sliding sleeve so that's ok.

[Fridge]

Thanks @Paul Coleman.

Pity the workshop manual wasn't up to date. I've spare hardened washers.

[Lotusfab]

Thanks. I believe you took the body off. I keep thing about this, was it worth it?

As far as I know the gearbox hasn't been rebuilt. I have found a company in Leaherhead that came well recommended. This gearbox is very simple so hopefully a reasonable cost just to check it. It worked great when I moved the car but as it's all coming out might as well get it done.

[Lotusfab]

All the kit arrives today to remove the engine. I have reviewed the workshop manual and it does say to remove the engine and gearbox as one unit. This is probably so you don't bend the shaft when separating. As the whole thing only weighs about 190Kg I'm going to remove it in one unit. The interior is nearly out, just the dash to go. I may take the body off anyway. The two annoying bits are probably the engine undercover holder, which is riveted and will have to come off and the steering columb which will have to be split. It has been quite quick to get to this stage, probably because I know the car. Last time the research took as long as the work. I need to buy some 4x2 and concrete blocks,to facilitate a body lift and plywood as I'm doing this on rough ground. Once out I will move the engine to my workshop where it's much nicer. The manifold will be going off to Pete at PNM for a totally refurb and weld.

[Fridge]

Good luck Fabian,

Don't underestimate the amount of area you need to move the crane into place etc, as uneven ground could be both annoying and troublesome.

Great photos in that @Buddsy (?) link.

Personally, it's a body off job for a really thorough restoration, but I understand the compromises you have to make sometimes.

[Andyww]

1 hour ago, Lotusfab said:

Thanks. I believe you took the body off. I keep thing about this, was it worth it?

As far as I know the gearbox hasn't been rebuilt. I have found a company in Leaherhead that came well recommended. This gearbox is very simple so hopefully a reasonable cost just to check it. It worked great when I moved the car but as it's all coming out might as well get it done.

I am not sure what they would be able to do though by looking at it. It might be worth seeking Harry Limmens advice on this. The last thing you want them to do is throw parts at it as they are hugely expensive. If there is a known issue, for example on mine its slow into second, that could be addressed by replacing just that synchro cone, which I intend to do at some point but not sure if this type of issue can be identified with it static. Even the bearings are very costly I believe so there arent any "preventative maintenance" parts.

On the other hand on my first Esprit when I drained the gear oil a big piece of tooth from the crownwheel fell out with the oil and that kind of thing is pretty visible with the cover taken off.

[910Esprit]

1 hour ago, Lotusfab said:

As far as I know the gearbox hasn't been rebuilt. I have found a company in Leaherhead that came well recommended. This gearbox is very simple so hopefully a reasonable cost just to check it. It worked great when I moved the car but as it's all coming out might as well get it done.

I was o writing a reply at the same time as Andy.   I think we have the same view  - bear in mind many of the parts are close to obsolete, so are expensive.   Cant see you getting much change out of £1000 even for pretty much a straightforward strip & reassemble, with no advantage over what you already have  Personal choice, but I'd leave well alone.   Should you subsequently find it needs doing its not a difficult box to remove. 

 

 

Edited May 31, 2017 by 910Esprit

[Fridge]

Have you tried Voights on the Wirral?

They know the Esprit gearbox well by all accounts. I just had my local transmission specialist refurbish my S1 box. Replacing the drive shaft bearings, diff bearings, oil seals and gaskets. It was generally in very good order. Cost me £550 plus parts (£450).

[910Esprit]

David - Who do you use in 'this' area?  (I'm in Cowbar at the moment)

[Fridge]

9 minutes ago, 910Esprit said:

I was o writing a reply at the same time as Andy.   I think we have the same view  - bear in mind many of the parts are close to obsolete, so are expensive.   Cant see you getting much change out of £1000 even for pretty much a straightforward strip & reassemble, with no advantage over what you already have  Personal choice, but I'd leave well alone.   Should you subsequently find it needs doing its not a difficult box to remove. 

 

 

There wasn't much wrong with my gearbox, but since I could not run the car before total strip down I had the box refurbished. I have found this to be very useful in the past with other cars.

The S1 box only had standing damage to the drive shaft bearings, which would have rumbled in use. So the process was worth it. Hopefully... we'll see.

[910Esprit]

Last time I neede one (crown wheel) I went down the 2nd hand route for £550 - Its been fine for the last 5 years.  However, I have noticed they dont come up on ebay so often now

[Fridge]

Just now, 910Esprit said:

David - Who do you use in 'this' area?  (I'm in Cowbar at the moment)

Crowbar!!!!!!!!!!!!!!!!! x10 to the power of 100.

 

I live in Saltburn-by-the-Sea, but I'm restoring the car on Teesside. I used Paul at Lagonda Garage/KC's Hot Rod place in Cowpen Industrial Estate, Billingham.

DM me and I'll forward his details when I'm back at the desk. As I'm assembling the chassis and running gear at present.

They are on Facebook and the t'interweb.

[910Esprit]

Cowbar (Staithes)  5 miles up the road...  I was in Saltburn yesterday 

[Andyww]

Just thinking: If the box is going to be stripped it would make lifting out the engine a whole lot easier if the rear housing was taken off first as this is the only part which fouls the body, otherwise it could be lifted straight up.

Removing the rear housing is easy although the large nut on the end of the shaft really need the car to be on the ground and handbrake on/chocked to lock the transmission. The nut with the speedo drive attached, which needs a special tool does not need to come off.

[Lotusfab]

Thanks Lads, all good advice. Sorry Buddsy I thought I saw a picture of just your chassis. I've decided to take the body off at long last, otherwise it will always annoy me. In order to do it by myself(I put the S1 body back on by myself) I have designed the "Marvelous mechanical body lifter offer". What is it you ask? Four pieces of 2x4 cemented into the lawn. The two pieces of 2x4 that pass under the body with two extra pieces on the inner will lifting points. These cross members lifted bit by bit and pegged with coach bolts. Blocks being used until the body clears the chassis. Here's a badly drawn picture.

binnacle out today!

[Lotusfab]

Does anyone know how to remove the binnacle fascia. It's block by the light dimmer knobs. Do they just pull off?

[Fridge]

1 hour ago, Lotusfab said:

Thanks Lads, all good advice. Sorry Buddsy I thought I saw a picture of just your chassis. I've decided to take the body off at long last, otherwise it will always annoy me. In order to do it by myself(I put the S1 body back on by myself) I have designed the "Marvelous mechanical body lifter offer". What is it you ask? Four pieces of 2x4 cemented into the lawn. The two pieces of 2x4 that pass under the body with two extra pieces on the inner will lifting points. These cross members lifted bit by bit and pegged with coach bolts. Blocks being used until the body clears the chassis. Here's a badly drawn picture.

binnacle out today!

Please come up and do mine in a couple of weeks. I'll watch from a deckchair whilst supping a beer. I'll buy you an ice cream when you're done.

[Andyww]

Yes they just pull off but very tight. I use a puller for IC chips but you might not have one of those lying around.

For body off suggest concreting a 2-post lift into the garden  but you might need to catch the wife on a good day. To be honest garden space is wasted space when it could be used for cars.

[Lotusfab]

Ahh, will have to find something to pull them off with! The binnacle is still stuck on. Once I get the front off should be easier. How is the back of the binnacle secured? There are two bolts at the front??Tea break then back at it. The body lift machine must be gone quickly with no trace, I have been realiably informed!???

Once Binnacle is off dash will come out then all of front. I'm amazed at the condition of this car under the dash, it's like new! Shame to disturb it, hey ho!

[Lotusfab]

The seatbelt bolt order has always caused a problem, so here it is.insulation is immaculate, as it left the factory.

[Lotusfab]

Binnacle removal

 

easybwhen you know how it works! Two screws in the front fascia. Remove. Pull the rheostat knobs off, very tight! Remove the two screws a lotus genius has put behind the rheostat knobs. The fascia comes off. Take the screws out of instrument panel and it is loose. Remove screws under the binnacle that hold the side instrument panels. Pull it all out carefully. Remove six bolts that hold the binnacle, job done. Much easier than the S1. This car is a much better build quality. 

Took about four hours, due not having done a Turbo before. Now it will be easy next time! 

This is very cool. It transmits light to the edge of the switchs, made in England of course!

[Lotusfab]

I'm looking on a time limit so am expediting it along, its far more exciting - just like one if those diy shows!