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Bush Insertion tool T000T0541F - Lotus / Motoring / Cars Chat - The Lotus Forums Jump to content
Simon350S

Bush Insertion tool T000T0541F

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Haven't posted this in a specific tech section as its generic to all Esprits from 86 onwards, guess it could go in the Wanted section but it may get lost or passed by in there.

Need it to fit the new Lotus Poly Bushes, according to my dealer in Cardiff they do not have one as they are too 'NEW' to stock Esprit special tools!

Also asked them to order me one and they said they are no longer in stock! Bummer!

Struggling to fit these little blighters without it and theres 10 of them to do! Don't want to damage them as they are not cheap!

Thank you all in anticipation of plenty of offers of help :)


Chunky Lover

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What dont you have a C**k Simon?

Are you telling us you are a butch lemon?

This is shock news to me mate.

I think Thailand has doctors who specialise in creating what you need. See that bloke / woman who won I am a celebrity skating on ice Jesus Christ superstar winner.

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Alex, for the 4th time, you're thinking of the wrong bush again!


88 Esprit NA, 89 Esprit Turbo SE, Evora, Evora S, Evora IPS, Evora S IPS, Evora S IPS SR, Evora 400, Elise S1, Elise S1 111s, Evora GT410 Sport

Evora NA

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Ah, Thailand.

I'm reliably informed that this individual was still in posession of the aforementioned tool:

DSC_9678.jpg

DSC_9680.jpg


British Ambassador to Florida, New York, Denmark and Newfoundland.  And Sweden.

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Cant they just use a bit of turned plastic to push it in ? Thats what I did on mine, see if they have some on the 'Bay and cut it to length and use that.


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//Whispers//

Just use a vice and a socket, but don't tell Brian what you're doing to his lovely new polybushes.

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Socket n vice are good for removal, useless for insertion!

It's a tapered device that apparently gently squeezes the bulbous head and allows it to slide into what is a VERY tight hole. Without it the distortion is extremely painful!


Chunky Lover

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Surely you need some kind of lubricant?


British Ambassador to Florida, New York, Denmark and Newfoundland.  And Sweden.

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Lube it up, baby. That's what's needed here. Lots and lots of luscious lube and the head will slip into the tight hole with a plop.

Mmmmm.....

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Glad we're on the same page. I'm going to help Trevor squeeze his in at the weekend. Chris'll be there too!


British Ambassador to Florida, New York, Denmark and Newfoundland.  And Sweden.

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Bore and stroke are also important parameters to consider. But polybushing is a young man's game, involving sustained mechanical effort, and quite possibly the possession of antiflaccidity materials designed to keep the insertion tool elevated to the correct performance angle.

In any case, this entire thread had gotten far too polysemous (today's "word du jour"), and Simon's search for the ultimate "smokin' suspension," I fear, has had too many barriers erected on the pathway to the ultimate ride. :)


Being second is to be the first of the ones who lose.

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Simon,have you tried banging on the flange? :)

In fact the more I say banging on the flange the more it sounds like a small village in England.

Edited by punky

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Ah yes, the ol' "asphyxiated chicken" method.


Being second is to be the first of the ones who lose.

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I got bushes from SJ, no "Insertion tool" required, real poly bushes good stuff. 10 is only enough for the front, be brave do the back as well, it made a huge difference to mine.

Sparky, like the look of Thailand (got a friend living there must go and visit again)


Life is like a sewer, what you get out of it, depends on what you put into it. (Tom Leahrer)

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Roger, AFAIK the SJ items are far inferior to the ones specified by Lotus. They are an unknown item with no specifications to the materials and their properties whereas the genuine Lotus items have been thoroughly researched, tested and specified by the factories Engineers.

I would speculate that if you fitted the correct item you'd see the same improvement again on top of what you had when you replaced your original items.


88 Esprit NA, 89 Esprit Turbo SE, Evora, Evora S, Evora IPS, Evora S IPS, Evora S IPS SR, Evora 400, Elise S1, Elise S1 111s, Evora GT410 Sport

Evora NA

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I wonder what they'd make of the PUK ones ?

I know they are a lot harder than the ones SJ have (purple compound).

The nice thing about the PUK ones are that they are split - I donk know what affect they have on performance but they are 1 million x easier to fit etc.

Simon, I've never seen that tool you're talking about, can you use something like a mikalor clamp to squash the lip and then offer it up to the hole and push it in that way ?


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Just spent about 3 days answering your post Roger but my iPhone crashed and lost it all..........!!!!!!! :)

What Bibs said.....!!!! Plus more....!!!!!!!

Jon.... Never heard of one of those? Will take a look...!

Also.... No amount of lube will help me... Sometimes it's just TOO big and needs assistance!


Chunky Lover

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Just spent about 3 days answering your post Roger but my iPhone crashed and lost it all..........!!!!!!! :)

What Bibs said.....!!!! Plus more....!!!!!!!

Jon.... Never heard of one of those? Will take a look...!

Also.... No amount of lube will help me... Sometimes it's just TOO big and needs assistance!

Really really glad I went back through all the posts as that last quote nearly required an appropriate answer, especially with the emphasis on TOO!


Heaven is where the police are British, the chefs Italian, the mechanics German, the lovers French and it is all organized by the Swiss. Hell is where the police are German, the chefs British, the mechanics French, the lovers Swiss and it is all organized by the Italians.

You make something idiotproof, they'll make a better idiot

You think professional is expensive, just wait until you pay for amateur.

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What are your fabricating skills like Simon? Do you have the facilities to make something to ease the head of your massive piece into this inviting cranny?

I'm assuming that the Lotus tool you mention is some sort of funnel/tapered implement? Could you manufacture a similar sized doohicky from a C shape of sheet metal? You only need something to fold the rim of your bush back on itself before it slips into the tunnel of fun.

A generous helping of automotive baby oil and some manful but accurate thrusting and Bob's your next door neighbour's cat sitter.

(I'm currently fitting a set of PUK's yellow two piece bushes and springs/dampers. Piece of pee pee. I'll report back on what they do to the car.)

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Just to introduce a bit of sanity..you need to do a bit of fairly simple metalwork. Make a cone with the small end the diameter of the hole into which the bush has to fit, and a suitable taper. A paper or cardboard pattern is the first thing to make, then transfer the shape to your metal..I used some 16g sheet steel I had handy. Get some tube of the same inside diameter as the outside diameter of the link bush tube, cut a short length off to locate your cone. Fit it all together, bags of washing up liquid, use a suitable socket and extension to push the bush down the cone and into the link using a vice, hydraulic press, or any sort of force exerting thingy you can extemporise. It will work if you persist...I bought a new lower link for mine years back (previous owners jacking bent the original!) and it came minus bushes so I had to fit them and that's how I did it.

The idea of turning a similar thing from hard nylon or similar is good, too...but I didn't have a lathe back then!


Scientists investigate that which already is; Engineers create that which has never been." - Albert Einstein

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It is a cone shaped tool as suggested.

Don't have anything here to make one with, no sheet metal, no welding equipment to fix the cone, have searched and searched and can't find anything suitable <_<

Still, I'm keen to hear off anyone who does have one! There must be some out there somewhere???


Chunky Lover

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I see so it's like an ice cream cone that you push the bush into and it compresses it down.

I still think a jubillee or pref a Mikalor clamp (makes a better circle than a jubillee) can squash the thing enough to slide it in.


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