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tb3033

Don't attempt this...

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Just a warning to those who are tempted to skim the top of their brand new aluminium nikasil coated liners - don't do it.

With the block just about acceptably bored and a set of of the later liners in place the tops were some way from spec. The advice from the machinist was to skim the tops to one level with a caveat that the nikasil might chip. And chip it did, though only very slightly on one side. The top of the chip was well above where the rings get to and I would have taken the chance and proceeded with the assembly.

The problem was that small bits of very hard nikasil got caught between the cutter and very soft aluminum and have created enormous grooves. In sections the surface resembles a coarse nail file and the possibility of achieving a reliable seal non existant.

Towads the end of the year my intention is to replace the whole block plus liners and have (what is left of) the engine rebuilt by a profesional. That way I can at least sell the car and buy a Noble.

Ambrose

Edited by _ambrose_

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Upgrade today to remove Google ads and support TLF.

I'm sorry to hear you've had more problems, it seems to be never ending. Try to stay positive and I'm sure that the rewards will be great.

If you need any help, even just someone to swear at, give me a shout.

:santa:

Tim


It's getting there......

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Thanks Tim, I've decided to pack everything away and leave it alone, maybe until next year unless I get the urge to sell it on as a project in the meantime.

The problem I have is that I no longer really respect older turbo esprits from a engineering standpoint. The more I've learnt about engines it comes as no surprise that a non-intercooled, unmanaged, carburettor based, knock sensorless engine with thermal issues is(was) on its second rebuild in less than 65k miles. Couple this to a gearbox that you are afraid to use boisterously and it doesn't really add up to much more than mobile antique. Unfortunately reality never really lived up to my expectations. The only sensible option is to do that Audi V8 conversion but this is way above my comfort zone. An SE engine may be an option I suppose.

Anyway, I do wish you the best of luck with your project and that you manage to get some enjoyment from it.

Ambrose

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So are you miffed with the car and it's 25 year old technology? Or are you miffed with yourself and engineers you've employed for not fully understanding that technology?

Plenty of people run G Turbos on a regular basis without needing constant engine rebuilds, perhaps you're aiming your angst in the wrong direction.

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Fairs fair Ambrose, I feel for you I really do, and you know I've had similar issues to yourself, but please reread you previous post and reflect, you were warned the Nikasil might chip, and indeed it did.

That's caused you extra hassle and really hacked you off, but that's no reason to get frustrated with the design of the car.

I understand that your entire Esprit experience (from being ripped off on your original purchase if I remember right? thorough to your hassles with a certain so called mechanic) has been trouble strewn, but that really is no reason to blame the car design. At the end of the day you've been burnt by other issues.

Sorry to appear a little harsh, but if you're going to go public with a dissatisfaction of the Esprit as a car then you're going to have to expect some defence of it!


Regards

Mat

post-1-0302470001278592957.jpg

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Ambrose, I know how you feel, after spending quite abit of monry on getting my TE on the road it handled like a sack of ****, and put me off driving it. I finally decided to do something about it, so spent another

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Ambrose...I'm just about ready for the first start of my newly rebuilt 82 TE. I've had similar frustrations as you...piston/liner fits being far too tight on the new pistons and liners in my case, leading to one set of melted pistons, much fannying around and finally honing out some new liners myself, to give a 4 1/2 thou clearance....also a modification to the head gasket and water flow through the block. Whether any of this will work I don't yet know!! I do know that the original bores and pistons were still serviceable after 90,000 miles, and I wouldn't have touched the motor had I not had a series of mishaps, starting with a burst coolant hose, leading to the waterpump seal lunching itself, new waterpump fitted during which I changed the cambelt, got the tension and snubbers wrong and had it jump teeth, which resulted in bending all the inlet valves!! After that, I decided to change the pistons and liners whilst it was in bits...then destroyed this engine because of too tight piston liner fits (and going far too fast for far too long!)

This time I'm hoping for a better result!! However, had the coolant hose not burst, the original engine would still be running happily. I don't know what people do to them to need two rebuilds in 65,000 miles. Had you stuck with the original specification you'd have avoided the world of pain you're currently in....but that's half the fun, really, and sometimes things work, sometimes they don't...as we all know!! The suggestion of acquiring one new liner and machining the face in the block, then reassembling it all is probably the way to go. Don't let the Gremlins win!!!

Edited by molemot

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

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Er, GKP yes and yes.

It's all about expectations, obviously everyone has a different set and it seems plenty of people have them sufficiently fulfilled by the S3T. That's great, Im happy that people are happy. No doubt the largely joyless experience of Esprit ownership has finally affected my will to continue with it. I strongly suspect that I would have come to the same opinion about the engine eventually, the various meddlings of conmen/incompetents merely increased the rate of convergence. I respect the many owners that plough through the various problems on their cars and for 2yrs I've trod that path but it's now time for me to reconsider.

At this point I'm considering the 'end game' and questioning whether I really want to spend another

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Hi mate

Its sad to hear of your sadness that has stemmed from what was a passion for you. Its even worse knowing that all you angst is from others and not things that are a fault of your own.

I myself have become fed up with the never ending so called restoration of my 'once beloved' esprits but my issues are all of my own making, I've just dissapointed myself by proving that I am a lazy assed bum hole waste of space who can't drag his sorry ass out of the rut to make a difference. Don't get me wrong, I love the cars, I just resent my own attitude!

You have been different, every time you have been kicked in the nuts you've stood back up again without seeking vengance and soldiered on, and I've admired you for that.

I've never seen you car but from the photos and what I know of its past it seems a very nice example and it would be a shame to let her go to waste, finish the excellent work you've started, but don't throw too much money at it. I can sell you a brand new block if Lotus have run out of them, then I'd fit a new set of iron liners from one of the specialists with your SE/HC pistons and have fun driving her around again!

As much as people write off the G Turbos as being too fragile, so many people run them as completely standard and have much fun doing so, you could be doing very much this and finally you can drag her along to a meet and be part of the gang!

One day EVENTUALLY/MAYBE I'll be there too, maybe you can help by giving me a kick up the backside too!!!!


Chunky Lover

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