Lotus Elan

New Engine Build

PostPost by: rgh0 » Thu Oct 12, 2017 12:28 pm

I spoke to soon about the cover checking out all OK except for the back plate recess for the block gallery plug. I pressed the bearing in place, fitted the chain guide and fitted the dipstick tube. I then went to fit the pump seal in the front cover and discovered the drain hole behind the seal was missing :twisted:

Drilling this hole is not for the faint hearted as it goes in at an angle through a small bulge in the casing on the water side into the space between bearing and seal.

photo of missing hole - yellow mark is where it should be

img_3092.jpg and


hole in original front cover

img_3093.jpg and


original cover set up in drill press to get the angle right with the drill running through the hole. The new cover was set to the same location to drill the hole needed.

img_3094.jpg and


Hole in the new cover came out in exactly the right location. Happy with my setup and drilling :D

img_3099.jpg and



I will be talking to the well known UK supplier about the faults. I presume they get them all from the same source and they need to work on their manufacturers quality control.

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PostPost by: alan.barker » Thu Oct 12, 2017 2:58 pm

Well done for putting the hole in the good place. It gives you an early warning of pump seal failure.
I thought you were fitting a front cover with a removable pump capsule
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PostPost by: pharriso » Thu Oct 12, 2017 5:54 pm

Rohan, why is the shaft so off centre compared to the raised boss?

img_3092.jpg and


Hole drilled in the pad bottom RH corner seems off centre as well; I'd check these covers over before fitting them :roll:
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PostPost by: alan.barker » Fri Oct 13, 2017 8:05 am

Thinking about it maybe it was safer to drill from the inside to be sure of the position
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PostPost by: rgh0 » Fri Oct 13, 2017 8:36 am

alan.barker wrote:Thinking about it maybe it was safer to drill from the inside to be sure of the position
Alan


Yes initially I thought about that but the setup on the drill press was much harder as there is nothing flat on the front face to bolt it down on the drill press bed.

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PostPost by: Certified Lotus » Fri Oct 13, 2017 10:20 am

[quote="pharriso"]Rohan, why is the shaft so off centre compared to the raised boss?

Phil, the original is the same. Looks like the casting is just made that way, even the bolt holes are like that. It’s probably in the right location, the casting just has a “heavier” side.
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PostPost by: pharriso » Fri Oct 13, 2017 10:48 am

Certified Lotus wrote:
pharriso wrote:Rohan, why is the shaft so off centre compared to the raised boss?

Phil, the original is the same. Looks like the casting is just made that way, even the bolt holes are like that. It’s probably in the right location, the casting just has a “heavier” side.


Rohan's is not, look at his picture:

img_3093.jpg and
Holes look centred on bosses
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PostPost by: Certified Lotus » Fri Oct 13, 2017 10:54 am

Hey Phil it’s Glen, not Rowan. I think the OEM casting is also off. It’s an optical illusion the way it’s photographed ? Only way to tell is use a micrometer.
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PostPost by: alan.barker » Fri Oct 13, 2017 10:55 am

Rohan,
where was the front cover made :?
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PostPost by: rgh0 » Fri Oct 13, 2017 11:06 am

The front cover came from a UK supplier. I presume they are all made in the same location these days regardless of the supplier, probably somewhere in India or China ?

The bosses for the machining of the various bolt and bearing holes are only approximately located in the casting and are deliberately made oversize to allow for shrinkage and core shift. I presume there is some sort of machining setup jig to reduce the raw casting to the required critical machined dimensions and locate the holes accurately in the critical places.

The reverse engineering of the casting machining has got the back plate relief hole for the gallery plug slightly wrong and the person doing the machining on the day clearly forgot to drill the drain hole in true Lotus quality control tradition :lol:

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PostPost by: rgh0 » Sat Oct 14, 2017 11:25 am

Fitted the front cover and water pump today. Discovered the chain damper pad prevented proper fit between the front cover and back plate. Needed a bit of filing of the chain damper and relieving of the back plate to get clearance. You really need to check every item as you bolt it together these days as the new parts are not identical to the original.

The new chain damper is painted black - looks nice but it interferes with its proper fit. The original one was not painted and fitted better due to this. i had to clean off the paint.

I use hex socket countersunk UNC screws to replace the flat blade screws that Lotus used as standard and the suppliers typical send. Much easier to fit and replace as you cant get a screw driver straight onto the lower one

screws.jpg and
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PostPost by: alan.barker » Sat Oct 14, 2017 12:51 pm

I imagine you put sealant on the screw threads :wink:
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PostPost by: 2cams70 » Sat Oct 14, 2017 1:32 pm

Yes those holes are through holes. I imagine quite a few twin cams leak due to people neglecting to put sealer on these threads.
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