Lotus Elan

Recomissioning an Elan Sprint.

PostPost by: rgh0 » Sun Jun 22, 2014 12:20 pm

You really need reduced stroke rear shockers or a droop limit cable to keep the CV's within their angular limit

cheers
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PostPost by: au-yt » Fri Jun 27, 2014 8:30 am

The front calipers are out and stripped down completely, to the last nut and bolt. They looked horrible but after the wire brush look half reasonable. Getting the Brake hoses from the chassis proved interesting and after resorting to cutting the old hoses and carefully drilling down the center, from the hose side, the old fitting snapped off... win
Given I have the brakes in pieces I removed the booster, just as well its a mess inside.

I found this link to overhauling the booster and what appears to be a service bulletin the change from the MK2A to MK2B on a Volvo P1800 website.
http://volvo1800pictures.com/document/G ... d%202B.pdf

IMG_0740.JPG and


IMG_0742.JPG and


Looks another week ..................or so
Graeme
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PostPost by: robertverhey » Fri Jun 27, 2014 10:00 am

Well done you for taking on the booster as a DIY project. It's not particularly difficult. The hardest part is finding the ball bearing when it pops out and rolls under the nearest piece of furniture. Kits available from UK (and expensive for the 2B type) and if you need it re sleeved in stainless like I did, Burt Brothers at Villawood will gladly relieve you of $300 for the privilege! But a servo resleeved in stainless will outlast the car and its owner.

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PostPost by: au-yt » Fri Jun 27, 2014 11:11 pm

Hi Robert.
Wow thanks for the heads up on the ball I didn't realise there was one, but now I know I will look for it in the bin I placed underneath to catch what ever come out of the spheres!

Stokies's in Miranda (Weldon brake and clutch) I will get to do the sleeve and and they can supply a kit so they tell me, but I will wait and see on that. I will take the whole unit to them today so then get the correct bits.
as I am aware there is 3 versions of the one case.

I am more than happy to have a go at the booster myself however I may finish getting Stokies's to do it.

I have another project and am busting to get back to that, and after 4 months of sorting the Elan I just want drive it!

Cheers
Graeme
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PostPost by: au-yt » Tue Jul 08, 2014 9:19 am

Hi All
I am waiting for the booster to refit that. I have also decided to change the brake fluid type to DOT5 because of its reduced ability to absorb water. Expensive but I have been told that Harley Davidson shops are the cheapest place to buy it.

The front calipers took some cleaning up and I have treated them with deoxidine which turns cast material dark grey, and a coat of high temp silver. I have a brand new set of Calipers but I would prefer to save them.

I also made a numberplate cover for the NSW H plates as they look very cheap. I will make another front but I am having trouble bringing myself to drilling holes in the car for the plates.

The Car had external mirrors next the side repeaters, I am told that was a requirement in the UK is this correct.
IMG_0528.JPG and

Cheers
Graeme
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PostPost by: rgh0 » Tue Jul 08, 2014 10:33 am

I am not sure Dot 5 fluid is a good idea for a Lotus. I tried it in my Plus 2 and the Girling booster did not like it and became very sticky in its action. I ended up flushing the system and going back to normal fluid. Soon after I also had to replace the master cylinder and clutch slave cylinder seals. Though I am not sure if all that was related to the fluid or just was going to happen anyhow.

The greater compressibility is also a negative as it results in a softer pedal feel especially with higher temperature use. I suspect the Elan brake system runs at higher pressures than modern systems especially on bikes, given its relatively small pistons which probably make this soft feel worse.

While water does not dissolve in the Dot 5 silicone fluid and lower its boiling point, water still gets in past the seals overtime and sits in the callipers causing corrosion and boiling when they get hot. So you still need to change it out regularly which gets expensive.

However not a lot of hard data so it would be interesting to see your experiences.

cheers
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PostPost by: au-yt » Tue Jul 08, 2014 10:53 am

Hi Rohan

I am glad I mentioned it, thanks for the insight and , I will esquire with the guys at Brandon's as to there comments.

Regards

Graeme
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PostPost by: pharriso » Tue Jul 08, 2014 8:43 pm

au-yt wrote:
The Car had external mirrors next the side repeaters, I am told that was a requirement in the UK is this correct.
IMG_0528.JPG

Cheers
Graeme


Yes those side repeaters were a UK requirement.

I can tell you that the mechanic that did a lot of your dash wiring was aerospace trained due to those neat tied string knots, pre-tie wrap of course!
Phil Harrison
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PostPost by: types26/36 » Tue Jul 08, 2014 9:06 pm

pharriso wrote:Yes those side repeaters were a UK requirement.


I dont think that is correct, as I understand it only vehicles from the 1st April 1986 had to have side repeaters which was long after production of the Elan had ceased. (see page from testers manual)
http://www.motuk.co.uk/manual_140.htm
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PostPost by: pharriso » Tue Jul 08, 2014 9:43 pm

Strange, something made Colin put them on, they certainly don't add lightness & all late UK cars had them... :shock:
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PostPost by: silverlink » Wed Jul 09, 2014 8:26 am

Could it be Graeme is referring to the external wing mirrors and not the indicators? if so then no, wing mirrors were not a requirement in the UK when the Elan was in production it became law much later.
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PostPost by: au-yt » Wed Jul 09, 2014 8:59 am

Ian
You are correct I referring to the Mirrors not the indicator repeaters.

The car appears to have had two different sets fitted at some stage as there is a dipple in the paint suggesting that.

I am not a huge fan of mirrors in that location form visual standpoint and practical reasons!! one more to reach over...

Regards
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..................................................Age doesn't matter unless you are a cheese................................................
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PostPost by: au-yt » Fri Jul 25, 2014 9:21 am

Finally some progress. I have repaired where the booster mounted and remade the baking plate for the booster
IMG_0744.JPG and

IMG_0747.JPG and


The Fully rebuilt booster is back after having the 5 bores sleeved in stainless, with new seals and fresh coat of paint. the only part he couldn't get was the check valve so I have a remote in line one to go in.

IMG_0749.JPG and

IMG_0754.JPG and


New Brake lines and Overhauled calipers
IMG_0751.JPG and


This weekends Jobs are to fit the other calipers and hoses bleed brakes and mount the number plates.

Cheers
Graeme
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PostPost by: billwill » Fri Jul 25, 2014 11:02 am

You probably need some form of droop limitation to go with those Mike Miller shafts.

You can have a steel hawser cable limiter or shorter damper shafts.


Plenty of discussion on this forum about this issue.


<later>
Ah, I see Rohan already told you that.
Bill Williams

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PostPost by: au-yt » Sat Jul 26, 2014 6:31 am

I will look into some limit straps similar to what one of my previous cars had that was a very heavy 20mm wide nylon strap, I have worked out that it can be attached where the seat belt to chassis bolt goes there is room to fit a D ring and then under the spring platform attached via a T bolt clamp, it that way I am not modifying any of the car.
Elan rear Sus and strap.JPG and


Cheers
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