Lotus Elan

Cosworth YB Turbo Into Elan

PostPost by: Chancer » Fri Sep 21, 2018 9:28 am

Steve.

Look at bighead bonding fasteners next time.

Being a functional rather than decorative fastener they wont look as slick as your creations though!
Chancer
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 1391
Joined: 20 Mar 2012
Location: Northern France/ Sussex UK

PostPost by: stevebroad » Fri Sep 21, 2018 12:30 pm

Chancer wrote:Steve.

Look at bighead bonding fasteners next time.

Being a functional rather than decorative fastener they wont look as slick as your creations though!


I have used those on the carbon seat I made. However, they aren't available in the exact size I require and, as they are made of steel, are very heavy :-) Also, with Bigheads being around £2.50 each, I saved myself £75 using aluminium I already have. Time spent making them isn't an issue :-)

20161214_161254.jpg and
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: Spyder fan » Fri Sep 21, 2018 4:36 pm

stevebroad wrote:Had my first walk around the car since getting it back from having the wiring completed, making a list of jobs still to do. Probably missed a lot but this is something to work on :-)

Secure intercooler
Modify radiator brackets to allow repositioning.
Fit air filter box
Finish air intake pipework
Fit header tank pipes
Get header tank filler cap
New pipe from overflow bottle to header tank.
Make new exhaust heat shields in CF
Fit wiper motor (either fix original or replace)
Finish front bulkhead and add heat shield material
Finish engine bay bodywork
Secure and adjust steering rack/rod ends for bump steer
Finish front clip
Fit injector rail and injectors
Connect up loom. Adjust position and wire lengths where necessary
Repostion ECU support bracket
Fit dash cover and cut hole for access
Fit screen wash jets and piping
Weld in additional roll cage tubing behind seats
Fit roll cage cushioning
Fit interior panels
Make doors and glass
Secure glove box door
Secure switch panel
Secure centre console and tidy up edges
Make front screen
Make and fit new roof and rear screen
Sort out fire supression system
Fit EGT and Lamda sensors
Fit oil filler cap
Get and fit plug leads
Fit plugs
Secure fuel tank and nitrous bottle
Get new electric bottle opener (or fix old one)
Fit fuel filler cap
Fit rear lamps
Finish droop limiters
Tighten ALL nuts and bolts, marking as I go.
Door locks and hinges
Get seat belts and fit
Parachute bracket
Under floor trays, side splitters and strakes
Rear view mirror
Fit and wire up remote tyre temp sensors
Change front springs
Make new radiator bottom hose
Fit hose clips to header tank hoses and secure
Fit exhaust box and cover
Fit heat shield material behind exhaust box
Fit boot
Bond in floors
Bolt on exhaust manifold and turbo
Fit turbo support strut
Reposition alternator/battery cable
Repostion loom through bulkhead and fit grommets/covers
Final fit of loom, adjusting wire lengths where necessary
Connect battery
Sort out wheels and tyres


Talk about " Note to Self"....... I am taking inspiration from your thread for my next project, it won't be on the same scale but it reinforces my normal "don't tell me I can't do that" philosophy.
Kindest regards

Alan Thomas
User avatar
Spyder fan
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 2458
Joined: 11 Jun 2009
Location: Kent country & Sussex seaside UK

PostPost by: stevebroad » Fri Sep 21, 2018 7:23 pm

Spyder fan wrote:
stevebroad wrote:Had my first walk around the car since getting it back from having the wiring completed, making a list of jobs still to do. Probably missed a lot but this is something to work on :-)

Secure intercooler
Modify radiator brackets to allow repositioning.
Fit air filter box
Finish air intake pipework
Fit header tank pipes
Get header tank filler cap
New pipe from overflow bottle to header tank.
etc

Talk about " Note to Self"....... I am taking inspiration from your thread for my next project, it won't be on the same scale but it reinforces my normal "don't tell me I can't do that" philosophy.


No such thing as can't, well, not many. However, there is no such thing as a problem in my lexicon, only challenges.

Easy stuff is boring, difficult stuff is fun. Also, doing something that appears to have not been done before gives a real buzz :-) AND I love making things, always have done.
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: stevebroad » Sun Sep 23, 2018 4:30 pm

Front and central aero panels in position. Next task is to fit the fasteners. After that I need to add some additional sections to cover the holes between the front tyres and existing floor.

front-and-central-undertrays-in-postition-230918.jpg and
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: Chancer » Sun Sep 23, 2018 10:20 pm

That should be a "Spot the Elan" photo contest :lol:
Chancer
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 1391
Joined: 20 Mar 2012
Location: Northern France/ Sussex UK

PostPost by: stevebroad » Sun Sep 23, 2018 11:26 pm

Chancer wrote:That should be a "Spot the Elan" photo contest :lol:


:-)
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: rgh0 » Mon Sep 24, 2018 10:09 am

Hi Steve

Time to get yourself a MaxJax or similar to get the car up in the air with all the under body detail work your doing rather than blocks of wood.

Also makes it much easier when you need to do a full check of under body, suspension and drive line before the next race.

cheers
Rohan
User avatar
rgh0
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 7092
Joined: 22 Sep 2003
Location: Melbourne, Australia

PostPost by: stevebroad » Mon Sep 24, 2018 11:24 am

rgh0 wrote:Hi Steve

Time to get yourself a MaxJax or similar to get the car up in the air with all the under body detail work your doing rather than blocks of wood.

Also makes it much easier when you need to do a full check of under body, suspension and drive line before the next race.

cheers
Rohan


Hi Rohan

I am only using the wooden blocks so I can install the aero panels. The car normally sits on this lift, which raises the car up to around a metre, which is perfect for working on it.

chassis-slide-02082011.jpg and


As there is nothing under the car that needs access (apart from the gearbox mount) it works perfectly. The 2 post lift restricts access to the car as the posts are usually in the way of the doors :-( Also, my garage space is a little narrow so it would greatly restrict movement. However, my new garage, when built, will be a little bigger so I am thinking of getting a 2-post lift for other vehicles.

garage-plan.jpg and


Regards
Steve
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: stevebroad » Tue Sep 25, 2018 5:57 pm

You spend 6 hours working on your car but it looks no different from when you started. Spent the day securing the underfloor aero panels. This entailed drilling and gluing in the top hat nuts I made a few days ago.

Still a lot of work to do to finish the panels and the remaining existing floor plus the addition of strakes to the panels as well as the side splitters. The final shape around the tyres will be done once the new wheels and tyres are fitted.

Also secured the front wheel speed sensor wires by passing them through the top wishbones. Added a couple of tabs to assist in locating the front clip. Adjusted the front aero panel straps so it fitted snugly to the splitter.

fastening-underfloor-aero-250918-8.jpg and


fastening-underfloor-aero-250918-6.jpg and


fastening-underfloor-aero-250918-10.jpg and


fastening-underfloor-aero-250918-9.jpg and


fastening-underfloor-aero-250918-3.jpg and


fastening-underfloor-aero-250918-2.jpg and


fastening-underfloor-aero-250918-4.jpg and


fastening-underfloor-aero-250918-7.jpg and
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: stevebroad » Fri Nov 23, 2018 8:38 pm

Looking for more ways to reduce weight, I started to attack the locks. Doing away with the door handles and lightening or replacing what remains with carbon fibre. Replaced latch cover with a CF version and also the rods connecting interior door opening handle and the latch.

door-lock-drilled-071118.jpg and


carbon-door-lock-cover-051118.jpg and


20181106_154221.jpg and


20181106_154238.jpg and


Made a prototype door button. Need to fit to car along with the latch to finalise design.

door-push-button081118-1.jpg and


door-push-button081118-2.jpg and


This work will remove over 2Kg. Also replacing OEM wiper motor with the rear screen motor from a Fiat Punto. Weighs 1.5kg less. Also converting to single wiper. Just need to reduce swept angle from 180 to 110 degrees.

fitting-wiper-motor-311018-4.jpg and
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: 661 » Fri Nov 23, 2018 10:38 pm

Interesting.
I'm converting my elan to using a Porsche 964 wiper system, again needing to reduce the sweep from 140 degrees to about 115. I'll keep both wipers.
If you've not seen the tinkering on the wiper system on 'Project Binky', it's worth a look, I think it was episode 18.
Last edited by 661 on Sun Nov 25, 2018 10:33 am, edited 1 time in total.
Graeme
S4 SE
S2 GTS
Peterson JPS Exige
User avatar
661
Fourth Gear
Fourth Gear
 
Posts: 664
Joined: 29 Mar 2012
Location: East Sussex

PostPost by: stevebroad » Sat Nov 24, 2018 9:07 am

Yeah, seen them all :-)

Over engineered as usual on this project. I am simply going to move the rod connected to the wiper gear a little closer to the centre, thereby reducing the rods movement. Using CAD I reckon about 6mm should do it.
stevebroad
Fourth Gear
Fourth Gear
 
Posts: 828
Joined: 08 Mar 2004
Location: Essex, England

PostPost by: 661 » Sat Nov 24, 2018 9:27 am

stevebroad wrote:Yeah, seen them all :-)

Over engineered as usual on this project. I am simply going to move the rod connected to the wiper gear a little closer to the centre, thereby reducing the rods movement. Using CAD I reckon about 6mm should do it.


The Pork system needed the actuator rod on the motor reducing from 24.5mm to 19.5mm using the rule of thumb.
The spindles also needed separating by 85mm. All good fun.
Graeme
S4 SE
S2 GTS
Peterson JPS Exige
User avatar
661
Fourth Gear
Fourth Gear
 
Posts: 664
Joined: 29 Mar 2012
Location: East Sussex

PostPost by: Certified Lotus » Sat Nov 24, 2018 11:19 am

Steve, I like your garage plan. Nicely laid out. Once it’s done you will have plenty of room for your next project or at least the constant fiddling needed on your current one.
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
07 Exige S - Wicked Road/Track Car
07 Exige S - Fast Road/Track Car
06 Elise - Track pack
User avatar
Certified Lotus
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 1201
Joined: 04 Aug 2014
Location: Princeton, NJ
PreviousNext

Total Online:

Users browsing this forum: Witofthestaircase and 1 guest