Lotus Elan

S1 Élan Rebuild - My Story

PostPost by: Certified Lotus » Thu May 28, 2015 11:17 am

I have a press in my garage. Was hoping the tubes would "drop in" after the heating process with just a few careful wacks of a hammer on a wood block. Your warning is well taken. Will press it on!
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PostPost by: Certified Lotus » Sat May 30, 2015 10:35 am

As usual I spent the week reading up on everything I should know about the next steps I will be taking in my rebuild. One of the subjects I came across was the careful installation of steering rack shims to adjust for bump steer. Mmmmmmm......I don't remember any shims when I removed the rack from the original chassis and the new chassis certainly didn't have any attached. I went back and looked at my photos (I photograph every part of disassembly so I don't forget anything) and was right, no shims.

Anyone have any advise on adding shims? The factory manual suggests they are absolutely necessary and critical for the proper bump steer.

Today's projects are mostly focused on a bunch of little part installs and minor things. Tomorrow my friend Drew is helping and we are tackling the reassembly of the rear bearing hubs and reassembly of the entire rear end including new TTR drive shafts and Koni shocks/springs.

Unfortunately my engine isn't done. The shop had a computer malfunction for the dyno and won't have it back up and running until next week. I know better than to rush this. Tuning on the dyno is optimal and worth the wait to have this done right.
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65 Elan S2 - 26/4055
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69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
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PostPost by: billwill » Sat May 30, 2015 11:49 am

I seem to recall that bump steer was covered in detail on this forum some time ago, but will take some finding.

Try ploughing though this lot of references.
https://www.google.com/search?q=%22bump ... 8&oe=utf-8

It's just possible that your chassis was spot on and didn't need any shims.
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PostPost by: Certified Lotus » Sun May 31, 2015 11:46 pm

Bearing carrier shock tube install day. What a process and massive effort! Not for the faint of heart and you better have the right tools otherwise forget doing this.

After reading everything I could about this subject and getting lots of great advise from this forum here is what we did (Drew came over to help as you need two people to do this effectively).

1) put the shock tubes in the freezer overnight
2) Preheat your propane gas grill to 500 degrees F. Put your bearing carrier in the grill, close the top and come back 20 minutes later.
3) Have a metal pipe to carry your very hot bearing carrier to your hydraulic press. (You have already set up the press for a 24 inch space to press). You need heavy leather welding gloves to move the bearing carrier around. Remove the shock tube from the freezer. Oil the inside of the bearing carrier. Insert the shock tube and press the tube into the carrier.

If you do this quickly it will press through the first part easily. The second part of the carrier takes more time (the tube has gotten warm, but it will press through)

Make sure you have screwed the shock retaining plate into the top of the tube before you start pressing.

IMG_4371-1.jpg and


IMG_4372-1.jpg and


IMG_4373.JPG and
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64 Elan S1 - 26/0379
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PostPost by: Certified Lotus » Mon Jun 01, 2015 1:08 am

Next was installing the bearings and the axle shaft. I had bought everything from TTR to insure we had all the parts and that everything would fit. They were very good about supplying all the circaclips and the proper bearings. The outer bearing fit like it should. Of course the inner bearing threw us for a loop. Its not what is identified in the repair manual and it has an o-ring on it. I communicated with TTR and they said to take the o-ring off. What they didn't tell me was the bearing is so large that the circaclip doesn't fit. We measured with a digital micrometer over and over again figuring we did something wrong. Nope, the bearing fits in the chase, but is too big to use the circaclip. After thinking about it we realized there is no way the bearing could come out so we figured all is well. If not, please let me know.

IMG_4375-1.jpg and


IMG_4376-1.jpg and


IMG_4377-1.jpg and
Last edited by Certified Lotus on Mon Jun 01, 2015 10:11 am, edited 1 time in total.
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65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
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PostPost by: Certified Lotus » Mon Jun 01, 2015 1:15 am

Once the bearing carrier was assembled it was time to bolt to the lower A frame to prepare for installing the shocks, springs and bumper. No problem bolting the carrier up. Now I need to install the shocks and the parts for the coil over suspension. (Not the diff bushings).

IMG_4381-1.jpg and


IMG_4391-1.jpg and
Last edited by Certified Lotus on Mon Jun 01, 2015 12:22 pm, edited 1 time in total.
Glen
65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
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PostPost by: Certified Lotus » Mon Jun 01, 2015 1:21 am

We also started running the new brake lines. Didn't get very far as I am missing the 5 way junction fitting. More parts to order!

IMG_4382-1.jpg and


IMG_4383-1.jpg and
Glen
65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
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PostPost by: Certified Lotus » Mon Jun 01, 2015 1:26 am

Lotocones. What can I say. The old ones fit perfectly on the new 26R chassis. The new ones did not! Seems someone decided that change is good and they made the "ears" larger so the lotocones wouldn't fit into the tower area for the mounting of them. Took me 2 hours of filing and fitting, filing and fitting to ensure a great final fit before bolting in (if I had used a grinder it would have taken 10 minutes). But I got it done and they fit beautifully.

IMG_4379-1.jpg and


IMG_4380-1.jpg and
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65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
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PostPost by: fatboyoz » Mon Jun 01, 2015 3:05 am

Glen,
Lotus produced two types of hub/bearing carriers.
The early type is referred to as an Issue 16. This type used 6206 type bearings for inner and outer bearings.
The later type is referred to as an Issue 18. This type used 6206 type bearing for the outer position and a wider bearing for the inner position.
Looking at your photos, it looks like you have Issue 16 carriers and you have fitted the larger bearing to the inner position. This is why you can't fit the circlip. There is also a dust shield that should be fitted between the inner bearing and the circlip (Issue 18 at least has this).
Looks like you will have to dismantle the carriers and fit the correct bearings if this is the case.
Cheers,
Colin.

Certified Lotus wrote:
Just installed this bearing and am somewhat surprised that it is so wide you can't install the circlip on the outside of the bearing (the inner circlip does fit). Anyone have insights to this?

IMG_4375-1.jpg

IMG_4376-1.jpg




Certified Lotus wrote:Next was installing the bearings and the axle shaft. I had bought everything from TTR to insure we had all the parts and that everything would fit. They were very good about supplying all the circaclips and the proper bearings. The outer bearing fit like it should. Of course the inner bearing through us for a loop. Its not what is identified in the repair manual and it has an o-ring on it. I communicated with TTR and they said to take the o-ring off. What they didn't tell me was the bearing is so large that the circaclip doesn't fit. We measured with a digital micrometer over and over again figuring we did something wrong. Nope, the bearing fits in the chase, but is too big to use the circaclip. After thinking about it we realized there is no way the bearing could come out so we figured all is well. If not, please let me know.

IMG_4375-1.jpg


IMG_4376-1.jpg


IMG_4377-1.jpg
'68 S4 DHC
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PostPost by: Certified Lotus » Mon Jun 01, 2015 9:53 am

Thanks Colin. Something new at every turn when rebuilding an early Élan :?

My friend Drew and I just couldn't figure it out. The original bearings were both the same size so we were suspect about the new wider bearing. I need to order new bearings and dust shields. Plus I understand spacers are also required?
Last edited by Certified Lotus on Mon Jun 01, 2015 12:23 pm, edited 1 time in total.
Glen
65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
12 Colin 30 - Lotus Racing Kart
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07 Exige S - Fast Road/Track Car
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PostPost by: rgh0 » Mon Jun 01, 2015 11:42 am

I would have hoped that TTR and any other of the usual suspects would ask whether you had Issue 16 or 18 rear hubs before selling you new bearings and shafts. They know the difference and should check if the buyer does not specify. If they know you have a Series 1 car they should check whether you have the original Issue 16 or have changed to the later Issue 18.

Always worthwhile checking on the forum for the tricks and traps in any job on an Elan before paying good money for the wrong bits :shock:

cheers
Rohan
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PostPost by: Certified Lotus » Mon Jun 01, 2015 11:50 am

Agreed Rohan. They knew I had an S1 so I am a bit surprised I had the wrong bearings. TTR has been good to deal with directly and they have been helpful on many things, so I am chalking this up to a simple oversight.
Glen
65 Elan S2 - 26/4055
72 Europa - 74/2358R
69 Elan S4 - 45/7941
64 Elan S1 - 26/0379
12 Colin 30 - Lotus Racing Kart
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PostPost by: elancoupe » Mon Jun 01, 2015 12:11 pm

I told TTR that I had the early carriers. They told me that the axles would suit either carrier, but did not tell me that the spacers would be needed.
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PostPost by: billwill » Mon Jun 01, 2015 12:31 pm

You managed to find a 5-way brake tube junction?

Where from, please?
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PostPost by: nomad » Mon Jun 01, 2015 4:44 pm

Glen has managed to fit the type 18 bearings to the 16 housings and, as he noted, it appears they would work but without the dust shield. What would be the problem with running them??? They appear that they would stay in place if there is something that holds the axle...without looking i assume there is.

[I have the correct ones from RD]

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