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Owen's Lotus Esprit GT3 Restoration - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
OwenGT3

Owen's Lotus Esprit GT3 Restoration

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Plusgas should be  better than wd40...................but your still going to shear a load, its a right of  passage for lotus ownership.😁

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5 minutes ago, mdw said:

Plusgas should be  better than wd40...................but your still going to shear a load, its a right of  passage for lotus ownership.😁

+1

premium penetrating oils are worth it.

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Had another go at getting the stubborn nut off the bracket holding the side of the front bumper on. I used my action camera to film under the wing, while viewing the live stream on my phone. This did help a lot in see if I was cutting in the correct area. I finally got the nut off by using a small cutting disc in my Dremel cable extension. It took about an hour or so to remove just the one nut, but it finally came off.

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Today I spent some time at the rear of the car removing some parts. I removed the tailgate, boot floor and petrol filler flap. Also all the vacuum pump , boot interior lights and screws in the gutter drain holes were removed. The trim tops of the quarter windows and petrol tank covers were also removed. The next part will be to remove the rear bumper, lights and exhaust trim panel.

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Well done Owen your making great progress. Just make sure it goes back to together as quick as I always loved the look of your car. 

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Looking good.

We know you will do a great job, as proved by your other projects. Really looking forward to this thread progressing!

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"Intellectuals solve problems; geniuses prevent them." Albert Einstein

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Not much work on the Esprit today (17.08.19), just removing some small parts. Removed some small spats that sit on all the corners of the bumpers. Also removed t h e tailgate locking plates, exhaust splash shield and rear boot breather vent frame.

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On 16/08/2019 at 18:53, OwenGT3 said:

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That looks remarkably like the state of mine, except in my case the water ingress appears to have been from the offside tailgate drain being too short and draining into the boot instead :(

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Good work, Owen.

I assume you'll be checking the rear aerofoil brackets? Mine were so rusty, they were on the point of failure.


Margate Exotics.

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On 20/08/2019 at 09:07, Chillidoggy said:

Good work, Owen.

I assume you'll be checking the rear aerofoil brackets? Mine were so rusty, they were on the point of failure.

I don't need them now as I have the late V8 stainless trim centre exhaust outlet. The old ones were rusty as hell, had to be cut off.

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Today (24.08.19) was spent stripping a lot more parts from the engine and engine bay. The engine is almost ready to remove, with just a few components attached. Both sides of the engine bay were also stripped, exposing the petrol tanks. Most components that sit on top of the tanks were removed. The exhaust system and the rear hanging frame was also removed. The loom was removed from the side panels and is now tucked up to one side. Again lots of reference photos were taken for rebuild time.

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The remaining items at the front of the car were removed. This includes the charge cooler radiator and the main water cooling radiator, along with the cowling. Some bolts had to be cut off, with a few coming undone by spanner.

The core on both radiators are beyond repair, so will need to have new ones.

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Today I dismantled the rear suspension. Most of the bolts came undone with relative ease, just a quirt of WD40 and the nuts could be removed. There were a few nuts that needed cutting off to remove the part, shock absorbers being one of them.

The lower link arm was taken off with the hub, so as to remove the lower pins on the bench. The pins will be cut off so not to crack and damage the hub. Brakes were OK to remove, but new handbrake cables will need to be fitted.

I also got the screw holding the clamp bracket out for the two injectors in the plenum manifold. A better screw will be fitted when assembling this item.

All items will be reconditioned, painted etc. before being refitted.

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Well today (17.09.19) the engine finally came out. I don't know when the last time it was out, but never in my 12 years of ownership. It wasn't too bad a job to do, some fiddly pipes to disconnect at the front of the engine, awkward in true Lotus fashion, but once they were off, the lifting was relativity easy.

I'd removed the inlet manifold to make fixing the lifting strap easier to go around the engine, which was actually nylon rope as that's all I had to hand. Putting it in I will use something better.

The car was at the lowest point on the jack system, but once the bolts had cleared the engine mounts, the engine lifted with ease, with just a little guidance near the rear of the car so it cleared the panel, Lotus don't give you much leeway in the engine bay.

Once cleared of the bodywork, it was just a matter of wheeling the lifting hoist back to clear of the car. I placed the engine and gearbox on a trolley with a wood sheet on top, luckily Lotus engine sumps are nice and flat to sit on.

With the engine and gearbox out, I finally separated the two parts. The bell housing was quite dry, so no rear oil leaks, but release bearing was dry as hell. It's surprising how heavy the gearbox is just on it's own.

The plan now is to get the engine on an engine frame to start stripping the head off. Other items on the engine and gearbox will follow the same for inspection.

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I haven't worked on the Esprit for a few day, but decided to get back on it, so today (14.09.19) I stripped the rear hubs down. Again as they haven't been to bits in possibly 22 years, bolts were seized, so first thing all fixings required a good squirt of releasing fluid.

I started to release the bearing hex head bolts, but these were seized solid, so decided to cut them off as it was easier. The lower link arm pin was also solid in the hub, so having heard the stories of cracked hubs, I decided to cut these off as well. This required cutting the pins down between the link arm and the hub pillars. Not much room for the cutter, but I was using the 1mm cutting discs.

With the link arm out of the way one side of the pin just fell out, but the other side had to be worked out. The steel to alloy side was the easy removed side, but the steel on steel side was rusted tight. Able now to be able to hold the hub on a solid surface, I was able to drive the pin out with a punch and releasing fluid.

The last item to be removed was the ABS sensors. Although I didn't need them when the car is rebuilt, I did want to remove them and save them, but I'm afraid this didn't happen. The sensors were corroded in the hub tight, so the only way to remove them was to break them out. This required removing the connection top, then drilling down the side of the magnets. This slot made the body of the sensor loose, so I was then able to hammer them out with a punch.

With everything removed from one hub, it was the same process on the other hub. Another item stripped ready for the big clean up of parts.

 

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Edited by OwenGT3
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