Lotus Elan

My Elan S3 DHC restoration thread (warning: picture heavy)

PostPost by: tomjones20194 » Fri Sep 28, 2018 2:42 pm

Brian -

Thanks for the pictures. Very helpful. Looks like the switches are set up about 80% correct. Not a big deal, but I may eventually get to changing back to stock configuration.
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PostPost by: tomjones20194 » Mon Oct 01, 2018 1:23 am

Had some time this weekend to work on my Elan. Removed the gas tank and emptied the 15+ year old gas out and cleaned the tank. Removed the brake and clutch master cylinders. Both have seized pistons. Removed the Weber carbs so I can get to the fuel pump which needs a rebuild. Ordered the following from Paul Matty: new brake master cylinder, new clutch master and shave cylinders, new braided clutch connector line, and fuel pump rebuild kit. No idea on how long shipping will take as this is the first time I have ordered from them. Here’s a couple of before and after pictures:

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Looks like I will also need new carb spacers and o-rings

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PostPost by: knockoffnut » Tue Oct 02, 2018 10:41 pm

The S/E would have been delivered with chrome strips along the rockers. These were often removed but you may see the holes if you strip the body during restoration. S/E also included knock off wheels. My understanding is that the black nose badge was used for a year after the sad passing of Jim Clark.
1964 S1
1965 S2
1967 S3 SE DHC
Frankentwincam
Seven S2 A
Seven S2 F
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PostPost by: tomjones20194 » Wed Oct 10, 2018 12:14 am

Very successful weekend working on my Lotus. Received the shipment from Paul Matty on Friday...

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Removed the fuel pump and rebuilt it using the rebuild kit from Paul Matty

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Rebuilding it requires removing the one-way valves in the center of the unit. They are held in place via small metal tabs created with a die or stamping process. Had to take a dremel to remove them.

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Put new valves in and took a punch and created new tabs to hold them in place. Here is it reinstalled.

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Got the new brake and clutch master cylinders installed and cleaned and reinstalled the carbs with new spacers and o-rings (thanks Michael!)

Bought a new battery, cleaned the starter connections, plug wires, fuse block, voltage regulator, new oil and filter and flushed the cooling system.

After a turning it over a few times and giving it a good dousing with carb cleaner I got it running!! Let it warm up and it idled and ran very smoothly. Quite surprised at how well it ran in fact. Especially since car has been sitting for over 22 years. Tried posting a short vid clip of it running but the forum site says .mov are not allowed.

Up next are brakes and clutch... :fingerscrossed
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