Esprit Turbo project car - part3 - the further continuation

[Lotusfab 3,174]

Thanks Richard, I have located the fan warning light- easy with no binnacle or windscreen and discovered that. I will publish the solution for the fan relays when I solve the puzzle if anyone is interested?

[Lotusfab 3,174]

Radiator shroud back on!

[Lotusfab 3,174]

I have now connected the fan harness. On inspection I would say someone has doubled the wires for the fan light onto the fan control relay. Why? I will have to take it all to pieces and split them back. 

The black piece is definately an old school fuse holder. I have found a replacement on eBay. It's would really help to save time if anyone has a picture of the wiring in the three relay block? If not I'll have to rewire and get it to work which always takes ages! 

[Andyww 1,278]

Cant help here as I modified mine unfortunately.

[Gotti 205]

Sorry i can't help.My Essex dont have the thermal trip.I have a two relay block 

[Lotusfab 3,174]

Thanks for the picture. I have seen three variations of wiring so far! Maybe I will have to test the circuit and rewire as necessary. It seems a third relay may not be required.

I have given up for today. I have finished the front apart from the lower spoilers. I have tapped all of the rivnuts and put two new ones in just a matter of bolting it on. Then I only have the radiator pipes to connect. The fan loom is connected but still trying to work out the wiring configuration. It only has similarities to the wiring diagram. May have to test it as is and try to understand how it is wired. I can do it but it's a long process! 

[Andyww 1,278]

The third one is the horn relay.

 

[Lotusfab 3,174]

[Lotusfab 3,174]

Front disk to hub spring washers 3/8 UNF26-34ftlb

[Lotusfab 3,174]

The brown thing was identified a a fuse holder. Here's a new one Identical, now fitted.

Ive had some fun fitting the new hubs and bearings one side done and I need a rest! I used a dial guage for the first time. I decided I don't like it and it's probably more accurate by feel which is how I have always done these bits! 

Note that bearing on the spindle was just resting I had to take it off and got the bearing seal first.

It's so much quicker to take to pieces than put back together. The main problem is loosing pieces! 

[Lotusfab 3,174]

Need a break from this now!

heres my solution to the silicon rad pipe and thermostat.

interestingly my pipes in the engine bay are different to the parts manual! 

The lower picture I am replacing all the pipes with silicon. The problem is 32 mm is too slack on the pipe. So have ordered 30 mm to see how this fits.

[RichardJGC 372]

Hi Fabian....dont forget the heater only pipe arrangement is slightly different, utilising pipe 047 whereas the a/c one uses pipe 048?

 

 

[Lotusfab 3,174]

Thanks for the diagram, that's my set up! I wanted to have a rest but this Lotus obsession has a grip on me!Bit of a cheat, it's not fixed yet the silver bit has to be cut and fitted, but at least the black is done! 

[DaKa 48]

Great postings Fabian, I love your attention to detail here.

Just one 'self' interest looking at the last set of pics - the aerial fitted - where did you source it and can it be accessed through the inside of the cabin by removing some of the side panel(s), or, must the drivers door be removed?

I didn't get a definite answer when asked recently.

Thxs

[Lotusfab 3,174]

Thanks. The aerial was an old school of eBay. The door needs removing. The originals aerial was made by Nippon Antenna, th8s is why NA is written on the side of the top chrome bit. I believe old jaguars use this aerial. I can tell you in my opinion the best solution is to use an aerial threat has a remote motor and a drive shaft. You may have seen them? The motor could be under the dash and n9 need to remove the door! 

By the way the aerial is earthed to the front crossmember on the earth braid tha continues to earth the front door. Andy gave me some black heat shrink that Imhave used to cover the braid. 

[Lotusfab 3,174]

I lost a D washer that goes on the hub. They don’t make these any more. Happily Pete at PNM came to the rescue. He has lots of parts that are not on the website and knows just about everything about the Lotus. Highly recommended as are S and J and Lotus bits, without whom it would be very very difficult to rebuild one of these.

[Lotusfab 3,174]

Just started to cutout the silver edging that fits to the top roof and cant rail. I posted how I did it on the S1 thread so will just post pictures here, there's  a lot of cutting and adjustments required for a perfect fit. Only tip make sure then end alignment is correct. Lotus were a bit hit and miss! 

These trim bits really make the car, it's all in the detail - sloppy job on the detail bits - sloppy finish overall! 

[Lotusfab 3,174]

Tailgate hinge

First make sure the bobbin is still bonded to the body. If it's loose there won't be nuch left if your immaculate bodywork after a few tailgate openings! Secondly the hinge arm pivots on the bolt and the bolt remains stationary, at least that's how it should work. Anything else and the paint will shred on the body! I plated the pivot bolts and used Engineering oil. They should be fitted before the trim. I had to rebond one of the bobbins with Epoxy, I like JB weld! incidentally don't fit the  B post trims until the silver bit and cant rails are done, I did it the tricky way!

use cloth to protect the paint or you will get scratches everywhere! 

The bolt sits pround under the hinge arm, so when bolted down the arm can pivot. Right back to the silver bit! 

[Lotusfab 3,174]

One side done. Like all things easy with practice. Use a little silicon and differentblength rivers so they fit! Lower part make sure the silver trim is far enough round the body so the cant rail fits under! 

So far I'm very pleased with the finish on this Turbo, still you can tell me iwhat you think when I finally get to show the car!

[Lotusfab 3,174]

[Lotusfab 3,174]

Nice Mota mate! 

[Lotusfab 3,174]

Front undersheild

I kept all of the original fixings and replaced them as they were all rusty! I measured them also, as you might expect knowing Lotus some of them were different to the parts manual listing. The undersheilds were held on by hex screws and spire clips. No8 one inch long - this type.

[Lotusfab 3,174]

I made a mess of the second silver trim piece, having said it was easy! They require extensive cutting to fit.  I marked  it and cut the wrong half off! Measure twice cut once springs to mind and  don't do work on a project when your tired! Easy to give advice isn't it. My problem is following it. Anyhow luckily I can buy another strip, although £34 down the swannee

Onto the doors and the centre trim. I have two new carririers to fit with the countersunk rivets. The original holes of course don't match the new carrier, that would be far too easy. I kept some of the original carrier. Will loosely fix it to either end hole then clamp a steel guide to them. Using th guide I will drill and rivet the new carrier on.

[Lotusfab 3,174]

Carrier strip

use a decent rivet gun, an eBay cheapie will make life very difficult and probably mess up the paint. Use a piece of soft cardboard around the rivet Fergie rvwhen the gun slips! Use countersunk rivets and a good straight edge. Filecthe edge of the rivets very carefully if they overhang, else you will see them through the waistband trim!

[Lotusfab 3,174]

On 29/05/2018 at 06:20, Lotusfab said:

Front undersheild

I kept all of the original fixings and replaced them as they were all rusty! I measured them also, as you might expect knowing Lotus some of them were different to the parts manual listing. The undersheilds were held on by hex screws and spire clips. No8 one inch long - this type.

These aren't no 8! They are bigger!

Don't worry I'm still alive and building this car! A new radiator hose, lovely! One tiny hose to you one giant leap for me!