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520Y - Continued

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Thanks for pointing that out - I had not registered that the bushes were Metalastic.

It looks like I will be taking the front end apart again then. At least its fairly easy to do at the moment

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  • 4 weeks later...

Thanks to Pete and Paul for pointing out that my lower wishbone bushes had separated. I'm now most of the way through fighting to replace them with poly bushes.


The drivers side bush pushed out easily but left the outer steel tube in the wishbone. A few minutes with a hacksaw split the tube and I could push it out in the vice.


The passenger side was another matter. That was firmly attached to the wishbone so in the end I took it to a friend's workshop where the 10T press soon saw it defeated.


I am now most of the way through rebuilding the suspension again. Fitting the new poly bushes is fairly easy, but as I always find, once the inner crush tube is inserted into the bushes they end up just that bit too wide to make fitting the large washers easy. However they are in now, so I'm almost back to where I started with the front end. 

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To finish off the gearbox before fitting it I needed to replace the rubber mount. These are still available from lotusbits, SJ Sports cars and I'm sure a few other suspects, however the £120 wanted felt a lot to me. As with the rest of the gearbox the mount is a standard part. It is 'Toyota 12371-34020 - insulator, engine mount, rear.

Looking online rockauto in the states have pattern parts for about £5, but I kept looking for a genuine part. claimed to have several available so I gave them a try. The part was £22, but shipping and import taxes were another £40 (from Japan). There was a cheaper but slower option that I didn't use.

10 days later the new gearbox mount arrived. £60 Isn't cheap, but it's a lot better than £120!

From this picture you can see why I needed a new mount.


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  • 1 month later...

Back in August 2021 I asked if anyone could recommend an engine rebuilder. I didn’t get a lot of response but decided to use a local Lotus specialist. Towards the end of the year I took the engine over to him so he could rebuild it as winter work.

That turned out to be a bit of a mistake as some 5 months later he finally admitted he would not be able to do the rebuild for a few reasons. However he did help arrange with a different but still fairly local specialist to do the work instead, and even took the engine over to the new person.

As it happens a friend had already recommended the second specialist, so I didn’t have any real concerns, and had just lost a bit of time but nothing more.

Talking to the rebuilder we agreed just to rebuild the engine to the standard LC spec. upgrading to HC spec seems to involve replacing lot of parts at pretty significant cost and effort - many of which were unlikely to need replacement due to wear.

In the end we found that the interior of the engine was absolutely filthy, which corresponded to it sitting for many years before the previous owner recommissioned the car. We also found that 2 of the liners were pitted beyond use, probably from having water sitting in them - so all 4 were replaced. However the crank was OK as were the pistons, so new rings and crank bearings were all that was needed.

I collected the engine in about June, and put it back into the car over the hottest weekend of the year in the middle of July. It must have been in the low 30's in the garage which mad for hard work.




The bearings in the alternator were pretty grumbly, and since the resin from the regulator was also leaking out I decided to get a replacement. That also looked a lot nicer with the now clean engine.

A question though - can anyone tell me how the new alternator needs connecting up? The terminals are labelled differently to the original





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  • 1 month later...

The answer to the alternator wiring question came from SJ Sportscars (who supplied the alternator) within a day of asking a question.

The large wire from the starter motor goes to the large terminal within the black shielding at the bottom of the picture above, and the small wire from the ignition goes to the small terminal within the black shielding. I had to swap a flag connector on the ignition wire to a ring connector, but otherwise it was a simple job.

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