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Ok it’s been a while? Yes I still have the Esprit and progress has been very slow! Have been tinkering with some bits and bobs and some parts have been removed/changed re-fitted, removed and some things are new to the project.

Have had some down time well in fact had a mental break down! which never helps and took a couple of months to get back to wanting to do anything with life and cars……..life sucks at times and things go to shit.

 

The Carcoon was a bit of a disappointment I still had a damp interior and mold was growing again! But it did help keep the car paint and bodywork clean and protected, so its worthy of being used but shame it does not do what it’s claimed to do.

 

The air ride is still fitted and has been upgraded with a computer based control system which lets me store 3 ride heights into memory and can be remotely changed with a key fob (can’t wait to catch people out when it’s parked!) This works really well as I was having issues trying to set the front at a consistent height and having issues with tracking/bump steer. Now it can be set accurately every time with just a press of a button.

Once I get some more miles done and found the ride height I can live with I plan to get it all setup as its not right at the moment steering feels like a hyper sensitive go kart at 60 mph and the slightest input/movement of the steering wheel is exaggerated to dangerous levels! The heavy steel air tank has gone and I have a twin pair of alloy air tanks.

 

Have extended the side ears around 15mm and made both just air inlet now, as the stock setup had the lower part inlet and upper outlet? The tailgate now has locking bonnet pins instead of the original catches, they kept undoing and the tailgate would open which was really annoying as the tailgate stays upright fully open when you get up to speed! I got stopped by the police and was oblivious to the fact the hatch was fully open while driving around! I can now lock it place (open a jar) to allow heat out.

 

Front radiator has been removed and in the process of fitting a bigger 60mm core Cosworth alloy rad, also changed the angle/rake of the rad. Engine bay boot floor area again has been ripped out and being redone, I think the issue with the rear hatch catches failing was due to the rear body flexing? I have made a steel frame to support the rear body, and rethinking the boot area again, was never really happy with the finished look so still working on that. Started to fit the new carpet, the hand brake gator is a total ass and just does not fit too good? These carpets are not cheap and never worth the money.

 

Will do a proper update soon with some pictures and more info.

Edited by V8-ESPRITS3

 
 
 
 
 

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Hi Rob, wodered what happened as you have been so quiet. Glad to here she is still a work in progress though and that you may at last have managed to solve the overheating issues. Sorry to hear you were under the weather for a while as well but now back and into the fight. Keep me posted on how it eventually turns out.

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Keep at it Rob......

Very interesting thread ......even if your a purist.......

These things have got to be done - just so you can say they have been.

Look after yourself - and enjoy the sunshine we are gonna have today


Only here once

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As above .you have done a great job .take it easy ....Mike

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Nice to see you back on things and hope you can iron out all of the teething problems. I look forward to seeing in action the new air management system. Btw, I really appreciate the advice you've given me on my air bag install, they are nearly in, just waiting on a new bracket (being laser cut as we speak) and I should be back testing by the end of this month.

Edited by CharlieCroker

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thanks guys ready to start back getting it finished........

 

Here are some pictures of the stock Esprit rad and the new alloy Cosworth rad, it’s a bit bigger and the core is much wider so I will gain more water capacity and hopefully improve the cooling.

18853612245_90b4aae586_b.jpg

18231047194_c452094027_b.jpg

 

Fitting fans to the new rad is easy as it has more brackets unlike the original item

18827382796_2bb536a604_b.jpg

 

Picture of how I had the original Esprit rad laying near flat due to clearance issues with running a low car.

18231048874_429430a321_b.jpg

Edited by V8-ESPRITS3

 
 
 
 
 

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Wow I never realised the S3 had such a tiny rad! I guessed it was more like the turbo.

 

Can you not fit a turbo rad?

 

Buddsy


 

"Belief is the enemy of knowing" - Crrow777

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Here are a couple of pics of the standard turbo rad. I fitted 3 x 11" electric cooling fans from Tripac

 

https://www.merlinmotorsport.co.uk/p/electric-radiator-cooling-fan-11-inch-diameter-rad-fan-11

 

31012012618.jpg

 

IMG_8414.jpg

 

Buddsy


 

"Belief is the enemy of knowing" - Crrow777

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Picture of how I had the original Esprit rad laying near flat due to clearance issues with running a low car.

18231048874_429430a321_b.jpg

 

 

I'm confused by the airflow management in this set-up. 

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the fans suck air? air flows over the top of the rad? picture angle probably makes it look odd? dont have any more pics as its all took out now. Was nearly the same as the stock setup fans behind the rad and rad on a slight raked angle.


 
 
 
 
 

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Mounting the rad is simple with the stock Cosworth side lugs, I just made up some mounts from alloy U section. Not yet finished, have some spare time today so hope to get it done today.

18856364771_aa07fd7aec_b.jpg

When fitting the rad I have decided to change the angle and have it sloped forward as apposed to backwards I have seen other cars like this? Not sure why it may work better? this actually worked out better fitting the hoses and fans with it angled forward, I cut the front lower floor to gain more room and to enable the rad to stand up a little more to increase the amount of air forced into it.

18848482982_1158c00e5a_b.jpg

18853615135_7bd849f70a_b.jpg

Also checked clearance for fitting the A-Frame and made sure it fits wouldn’t want to remove the rad every time I towed it! Yes I expect break downs! The car has given me no reason to trust it to be reliable………its still an old Lotus with Lucas and British Leyland parts at best. I still love it and still get a buzz from seeing it every day which is why we do it.


 
 
 
 
 

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I think the angle you have set the new cosworth one is much more like the original set up. The air flows through the rad when driving with the fans sucking air through when stopped.

 

Buddsy


 

"Belief is the enemy of knowing" - Crrow777

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18238002303_5f65fc482e_b.jpg

 

 

 

 

While I was under the car at the front I noticed a little leak from the small hose feeding the heater matrix, the joining tubes were rusted to hell and the other just fell apart when I tried to remove the retaining clips. That was a lucky escape catching that in time as that would have caused a major break down with all the coolant pumping out! All fixed now with stainless tube and new stainless hose clips.

18231040804_561a4c075b_b.jpg


I think the angle you have set the new cosworth one is much more like the original set up. The air flows through the rad when driving with the fans sucking air through when stopped.

 

Buddsy

maybe on the turbo? mine was tilted at the top backwards? also my S1 had the rad tilted top backwards?


 
 
 
 
 

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Oh right sorry. I see what you are saying now leaning forwards. I looked at the pics and thought it was top back.

 

Should work ok with the front forward I would think.

 

Buddsy


 

"Belief is the enemy of knowing" - Crrow777

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Indeed, yes. The more upright the rad the less you are trying to fight against physics. This new layout seems to be potentially more efficient. Keep going!

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All looking good. Just another thought, what about doing something Elise style with the front bonnet ? 

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yeah I like the idea maybe in the future but for now I don't want to get into body work and paint, cars been half finished for to long I want to get it back on the road and drive it, still have a long list of unfinished jobs........was also thinking of having the rear body flip up and over like a clam like on an F40.


 
 
 
 
 

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Yeah it's a lot of work but may help with hot air escaping from the rad.  

 

I'd love a clamshell, it'll make life sooo much easier.  I think someone on hear has already done it

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Im actually going to open the  radiator where the spare was similar to yours Rob and glass in an area that will lead to a louvered section on the bonnet. Also going to clam the extra body I have, along with making new grill and rear section to lose the big bumpers.

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Yeah it's a lot of work but may help with hot air escaping from the rad.  

 

I'd love a clamshell, it'll make life sooo much easier.  I think someone on hear has already done it

Yes it has been done many times, all race cars I have not yet seen it done to a road car?

 

18872945125_ec4d6b599c_b.jpg

 

18685230498_27294b1a11_b.jpg

 

18686775519_3ef6070feb_b.jpg

 

18872926295_11872e29d1_b.jpg

 

18686810589_48d3a79e3a_b.jpg

I hate the S3 front bumper! really want to fit a S1/S2 front bumper, another job added to the long list of things to do!


 
 
 
 
 

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On my quest to improve cooling getting more cold air into the engine bay is the biggest problem due to engine location and lack of space, engine size and exhaust. Lotus only fitted small intakes on the side of the car often referred to as “Ears”.

This is what the intake\outlets look like without the cover (Ear), as you can see the lower hole is for cold air intake and the upper for air out.

18250906934_d91fa56b13_b.jpg

I have made both holes now cold air intakes and made the outside cover (Ears) spaced out 15mm from the body to increase air flow into the inlets. The bottom hole is going to flow air towards the engine (exhaust manifolds) and the top hole is going to feed cold air to the air filter.

18876249141_99a1a58b2f_b.jpg

view from rear, most people may not even notice the difference at first glance

18868270802_48a2e679d7_b.jpg

also painted the fuel caps satin black, never really liked the colour coded nonsense

not sure if I am going to leave the fronts open or fit some sort of grill/mesh. Keeping them open will make life easier and less hassle cleaning the car.

18868270062_0b43b78724_b.jpg


 
 
 
 
 

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While I was in the mood for painting things satin black, I wanted to refresh my door frame trims. The door cap/seal was pitted with rust so I decided to remove it to do a better job as it’s hard to paint it in situ with the rubber glass seal, as it also had a few areas that needed paint under the seal.  The trim is held in place with 3 nuts, very small and a weird size (1/4) if you have a socket set with a small socket that you have never used with ¼ wrote on it now you know what it fits! Ah but you can not get it on because of the angle of the stems and the glass being in the way! Lucky for me I had a small ring spanner also in my arsenal. The threaded stems are rusty and just from the look of them they look like they will snap at the first tweak of trying to undo them! I squirted a good dose of WD40 and commenced the attack. I know why Lotus chose ¼ because that’s all the room you have to undo these sods ¼ turn, spanner off ¼ turn, spanner off ¼ turn, etc you get the idea! They are also fine tread and long fooken stems! You also have to remove the outer handle to get a very ridiculous chance of even reaching that end one. No doubt there is a easy way of doing this and me being a complete tool did it the hardest way possible. If you had small child’s hands and thin arms like sponge bob then it’s probably very easy. Ok after hours I relived them on their resting ground for most likely the last 30 years, drilled out the pop rivets removed the rubber seal and sanded them down and also the rear retaining plate. Painted them in black etch primmer and left them over night. Painted them satin black the next day, why is it when you spray with an aerosol can it will always splatter at some point and ruin the job? So had to wait again for them to dry, sanded back the ruined areas and painted again, Job done! then left them for another day for the paint to set nice and hard. When I started to fit the rubbers I found they had shrunk? They were now a good inch shorter than when I took them off? So you have to start at one end with a pop rivet, stretch the rubber to align the next hole and the again and again for each hole until complete. Then stand back and admire all your hard work with a rubber seal fitted all rippled and lumpy and looking like the tread of an old tyre rather than a smooth crisp black rubber trim I had envisioned. First tip of the day I forgot to mention you don’t have to remove the nuts completely just undo until close to the end, as you can remove the trim due to the door tops just having slots and not holes as the mounting points. You only find out when removed! So refitting is again a painfully slow process, and now they just don’t fit as good as they did, so a crappy couple of days wasted. Second tip of the day don’t remove them just paint in situ!

 

18711396498_e63f5e9d5f_o.jpg

 

The rear quarter trims got painted in situ!


 
 
 
 
 

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Here are a couple of pics of the standard turbo rad. I fitted 3 x 11" electric cooling fans from Tripac

 

https://www.merlinmotorsport.co.uk/p/electric-radiator-cooling-fan-11-inch-diameter-rad-fan-11

 

31012012618.jpg

 

IMG_8414.jpg

 

Buddsy

Buddsy,

does the turbo rad go full width of the car?


 
 
 
 
 

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I have modified the lower air shroud/duct to fit the new rad, just used sheet alloy and pop rivets. Fits snug around the rad, and also found some front turbo brake ducts and fitted them as well, can now route some tube to the front brakes or into the car for free air con!

18716398378_7d84fa2003_c.jpg

Not pretty but will help duct the air to the rad, once painted black should look ok ish. Well no will still look crap! But it can not be seen unless you’re under the car so if I run you over keep your eyes shut as the duct is going over you! and be a good chap let me know if you scratched the paint off……..


 
 
 
 
 

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Rad duct fitted with grill, just need to fit the front spoiler to complete the front under tray.

18737960509_63e4d0d37a_c.jpg


 
 
 
 
 

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