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Sorry, I couldn't help a teaser mock-up on the twin charge-cooler set-up. Engine will be running the optimised ECU set-up for the intercooled V8 and 1 bar boost.

I have the privilege of rebuilding and upgrading an engine for Simon Francis.  It's a nice engine spec with CP Carrillo forced pistons and h-beam rods.  We've overcome the rod width issue on Sacha's e

Cam covers had been painted inside and out, so the baffles had to be stripped, have the paint removed and then the covers drilled and tapped to re-secure.  Cam covers then sealed so the top-end is now

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  • Gold FFM

Ooh, those pistons look nice, can you accidentally forget to fit them instead of the originals. I know someone else who could give them a good home. 😄 

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Engines out.  Will split the gearbox and start tearing down the engine.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Broke my phone, but some images of recent progress.spacer.png

Block and covers stripped fully and cleaned and prepared for build up.

Some of the gearbox mounting threads were stripped in the block, so needed Helicoils.  Those will be necessary to mount the engine on the stand.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Characteristically good work from Mike.

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Mike,

really enjoy a thread like this!!

Love the valve removing tool.

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SAI threaded for blocking and continued with lapping the RH head.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Excellent as ever Mike, thank you. 

When I had the heads on my V8 ported and the valve seats CNC radiussed by Simon Armstrong at Ultimate Performance, I dutifully lapped in all 32 valves.  It took about three hours. When I proudly told Simon what I had done he asked, "What did you do that for? The machining is to such fine tolerances that you can put the valves back without lapping."

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Hi Ed,

That's funny. 🤣

I've also had a pair of ported heads from Simon.  He's a very talented engineer.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Correct.  I use a combination of chemical and physical removal.  This engine was at around 70K miles and in very good condition internally, but had high carbon deposits.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Lapping complete and both cylinders rebuild ready for installation

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Rings gapped and the IMS scotch key is prepared.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Hit a small snag..... one of the CP Carrillo rods was damaged by the local shop during the machining operation.  As it was the second set they had done, I did not inspect until now.  The rod is unusable, but it's going to be 8-10 weeks before I can get a replacement rod from the supplier.

Will focus on other jobs, but further build of the engine is delayed until the rod rocks-up.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Ah no...... me thinks they will have know about that 😢

Only here once

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  • 3 weeks later...

Looks super nice after the vapour blasting. Can it be done in situ, or is complete dismantling required?

Kind regards,

Jacques

Nobody does it better - than Lotus ;)

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