S1 Project car - part 2 - the continuation

[Lotusfab]

Veglia repaired and back in. Just waiting for steering parts to come.there now about a 5 mm clearance between the needles and the perspex.

easy job really.

incidentally I had a scratch on the inside of my windscreen It appeared after I let others drive it. Not sure when it happened. I was able to polish it out quite easily. You could feel it with your fingernail. I used a drill with felt pad and Cerium oxide. When I have more time I may remove some of the scratches on the exterior glass. They don’t stand out but I know they are there! 

[Djs44]

5 hours ago, Lotusfab said:

Veglia repaired and back in. Just waiting for steering parts to come.there now about a 5 mm clearance between the needles and the perspex.

easy job really.

incidentally I had a scratch on the inside of my windscreen It appeared after I let others drive it. Not sure when it happened. I was able to polish it out quite easily. You could feel it with your fingernail. I used a drill with felt pad and Cerium oxide. When I have more time I may remove some of the scratches on the exterior glass. They don’t stand out but I know they are there! 

That's good to know about the scratch removal - I have some scratches on the quarter lights that need sorting ..

[Lotusfab]

1 minute ago, Djs44 said:

That's good to know about the scratch removal - I have some scratches on the quarter lights that need sorting ..

Keep an eye on the temperature whilst your working, keep the disc moving and apply more water when the paste starts to dry out. This keeps the heat down, Two much heat could crack the glass. Took me about 40 mins with pauses to remove the windscreen scratch.

[Lotusfab]

All done, no play at all in the steering and Veglia fixed. Just needs a good vacuum and a road test!

[Lotusfab]

Well road test complete. For the first time my speedo works perfectly and my rpm gauge. The annoying rattle I always thought was in the binnacle has gone, it was the UJ I replaced!  S and J have updated their lower UJ to the correct one, so should work fine now if someone needs a replacement. I still recommend a more expensive refurb of the Originals.

[Lotusfab]

Well Nirvana didn’t last long. I came back from a drive yesterday left the car idling and it decided to dump all the coolant! Quick engine off and an investigation. You guessed it the failure was caused by a sub standard replacement part! It was the shaped hose at the front of the cylinder head. This hose has to deal with heat and a lot of vibration, because it goes from the moving engine to a fixed chassis point. Lotus strengthened it with cloth and stitching. The one I was supplied had none of this!you can see it split along its length. It has no reinforcement at all and is totally unsuitable for this application. The new one I bought about a year ago is the same. I cut through it and found no reinforcement. If you have fitted these pipes I suggest replacing them now before they explode! I will be using bespoke silicone reinforced.They are twice the price but the only workable solution. Anything else is a failure waiting to happen. I have had so many issues with parts and the situation is getting worse.

[shaunw]

4 hours ago, Lotusfab said:

Well Nirvana didn’t last long. I came back from a drive yesterday left the car idling and it decided to dump all the coolant! Quick engine off and an investigation. You guessed it the failure was caused by a sub standard replacement part! It was the shaped hose at the front of the cylinder head. This hose has to deal with heat and a lot of vibration, because it goes from the moving engine to a fixed chassis point. Lotus strengthened it with cloth and stitching. The one I was supplied had none of this!you can see it split along its length. It has no reinforcement at all and is totally unsuitable for this application. The new one I bought about a year ago is the same. I cut through it and found no reinforcement. If you have fitted these pipes I suggest replacing them now before they explode! I will be using bespoke silicone reinforced.They are twice the price but the only workable solution. Anything else is a failure waiting to happen. I have had so many issues with parts and the situation is getting worse.

Inferior replacement parts really are a major frustration with older cars. I had loads of issues with incorrect / ill fitting and poor quality replacement parts with my old Excel, I haven't needed too much for the Esprit yet but even the aluminium HVAC controls I ordered from PNM had to be modified to enable proper fitment. 🙄 

[Lotusfab]

Don’t buy an ignition switch for an S1 from the usual supplier it doesn’t work! I spent 3 hrs installing it as my original one was intermittent. The new one looked great and fitted. Tried running the car no fans or windows. Checked all the circuits with extensive diagnostics. Found the new switch can never work as the brown wire has to feed the white and blue/white when in the run position the same as the old one. Well is can only ever power the white wire in run position. This will lead to a loss of window motors and no cooling when driving! Potential engine damage. Great!😡😡😡😡😡  

Used the new pipe above temporarily whilst I wait for Lotusbits to make me a new one! I need to run the car. Now I have to rebuild the old ignition switch and its well past its sell by date!

[omegaman]

On 02/05/2023 at 14:10, Lotusfab said:

Veglia repaired and back in. Just waiting for steering parts to come.there now about a 5 mm clearance between the needles and the perspex.

easy job really.

incidentally I had a scratch on the inside of my windscreen It appeared after I let others drive it. Not sure when it happened. I was able to polish it out quite easily. You could feel it with your fingernail. I used a drill with felt pad and Cerium oxide. When I have more time I may remove some of the scratches on the exterior glass. They don’t stand out but I know they are there! 

Can I ask a question about your instrument front panel? How did you get it to stay in place? My clips hold the plastic back from moving, the front panel and perspex can still fall forward. Yours look like the clips actually hold the front panel. 

[Lotusfab]

53 minutes ago, omegaman said:

Can I ask a question about your instrument front panel? How did you get it to stay in place? My clips hold the plastic back from moving, the front panel and perspex can still fall forward. Yours look like the clips actually hold the front panel. 

Of course. The clips wrap around the Veglia lugs and there is a small gap where you squeeze in the perspex and metal instrument facia. Maybe someone has replaced yours with incorrect clips?  

[Lotusfab]

Car all repaired. Had no choice but to repair the original ignition switch. I cleaned it internally with a dremmel and wire brush, contact cleaner and greased the moving plastic and ball bearing. Where the tabs were poor I used epoxy to hold it firm after roughing the edges. I then drilled the steering lock to make a new ignition switch screw hole. I also replaced all the connectors on the loom and switch harness. The art to this is a correctly adjusted crimping tool and a very hot solder iron. Its all about the quality of your tools for a good job. Its now all working nicely. I have to resist the temptation to by new parts. They always seem to have issues. The originals are better quality and there always seems to be a way to repair them.

1 hour ago, omegaman said:

Can I ask a question about your instrument front panel? How did you get it to stay in place? My clips hold the plastic back from moving, the front panel and perspex can still fall forward. Yours look like the clips actually hold the front panel. 

If you post a clip picture I can tell you if its the correct part.

[Lotusfab]

2 hours ago, omegaman said:

Can I ask a question about your instrument front panel? How did you get it to stay in place? My clips hold the plastic back from moving, the front panel and perspex can still fall forward. Yours look like the clips actually hold the front panel. 

Responded on facebook. Heres a pic.

[omegaman]

My clips look the same as yours. 

 

[Lotusfab]

2 minutes ago, omegaman said:

My clips look the same as yours. 

 

Yep they are correct but installed wrong. The front of the clip must pass through the hole so it can hold the perspex and instrument mask.

[omegaman]

Great, thanks. I'll give it a go later.

[Lotusfab]

First mechanical issue since the rebuild. The SU fuel pump is continuously ticking. It should stop when the fuel pressure has built up. The pump was new when I restored the car. There are no fuel leaks, so I believe the pump itself has malfunctioned. Still safe to drive, but probably fuel contamination. I need the car for Newlands Corner tomorrow, so will fix the pump after. The SU pump has a built in filter, so maybe it needs a clean. Still very good fuel pressure and no carb leaks.

[Lotusfab]

Well the fuel pump fixed itself! Now working properly. I true Lotus fashion I am now removing the ignition switch again! I discovered its not turning completely off. Not sure why. Will have to removed the Araldite and examine inside. Does anyone know a source of new ignition switches that work?

[Paul Coleman]

On 25/06/2023 at 08:56, Lotusfab said:

Well the fuel pump fixed itself! Now working properly. I true Lotus fashion I am now removing the ignition switch again! I discovered its not turning completely off. Not sure why. Will have to removed the Araldite and examine inside. Does anyone know a source of new ignition switches that work?

Do these not work then?

https://www.sjsportscars.com/parts-and-accessories/SJ744.htm

[Lotusfab]

On 30/06/2023 at 19:54, Paul Coleman said:

Do these not work then?

https://www.sjsportscars.com/parts-and-accessories/SJ744.htm

 

On 30/06/2023 at 19:54, Paul Coleman said:

Do these not work then?

https://www.sjsportscars.com/parts-and-accessories/SJ744.htm

No. Unless the new one I have is faulty these will cause your car to overheat! Why? Well its pretty simple there are four wires. The brown is positive, blue/brown (assesories incl windows and fans), white all the other services, red/white start monetary position.

The original switch at first turn position connects the positive brown wire to the blue/brown, second postion- connects the Blue/brown and white wires to the positive. This switch in the second position removes power from the blue/brown wire leaving you with no accessories which include your windows and cooling fans. Installing it will result in all the coolant boiling out when the car gets hot, unless of corse my new switch has an internal fault which is very unlikely,  but not impossible. I have fixed and reinstalled the original switch which is now working.

 

[Paul Coleman]

3 hours ago, Lotusfab said:

unless of corse my new switch has an internal fault which is very unlikely,  but not impossible. I have fixed and reinstalled the original switch which is now working.

Yeah sounds like you have a duff switch to me. I've got a spare original somewhere if you get really stuck.

[drdoom]

I recently checked function of the OEM switch fitted to my early S2. In terms of "Accessory" function it remains live as the switch moves on to "Ignition". This seems to me as imperative, for reasons including those stated by Fabian.

As to wire colouring for the S2 we have brown/red feed to the switch, white/blue for accessory, white for ignition, and white/red for starter. 

[Lotusfab]

1 hour ago, Paul Coleman said:

Yeah sounds like you have a duff switch to me. I've got a spare original somewhere if you get really stuck.

Thanks Paul I found the fault with the original switch and repaired it. Seems to work fine now.

[Lotusfab]

Roger watching over the Esprit at a car show during the weekend. Another fault has developed. My seatbelt reels which were new from a well known supplier have now both failed! I replaced the drivers side some time ago and now the passenger side has failed. You can’t pull the belt out! I now use a professional seat belt supplier. She said the reels I had on she won’t sell as they are rubbish! I am annoyed they have both failed after only a hand-full of pulls, but I am more annoyed at all the extra fitting work this is causing! I also have to replace the high torque starter I bought. It is making noise. That was also new and totally unsuitable, as the mesh is all wrong. So frustrating lots of the new parts are rubbish - especially when are supplied by specialists. Despite all this I love the S1. Its not the fault of the car. Still waiting for the cooling pipe to be remade.

 

[Lotusfab]

If ye need webbing replaced, decent quality seatbelt reels or anything seatbelt related heres the place to go. Very reasonably priced Old school business.

http://fdts-seatbelts.co.uk

[madmax]

Absolutely - FDTS are an amazing old school company and their customer service I've experienced is second to none - so refreshing these days.

When I've spoken to them, a very knowledgeable lady often answers the phone - she's called Sue TAYLOR and I believe she's the MD.

Great products and great service - unbelievable to be honest!