free hit
counters
Esprit Turbo project car - part3 - the further continuation - Page 139 - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
Lotusfab

Esprit Turbo project car - part3 - the further continuation

Recommended Posts

IMG_5407.thumb.JPG.e4945393cc6bc4427127e64d7cb259df.JPGIMG_5408.thumb.JPG.91cddace05672936374d612de032a7cb.JPGThis panel arrived. Now I need to figure out the best way to convert the graphics?

Share this post


Link to post
Share on other sites

Upgrade today to remove Google ads and support TLF.

The Bond car inside

Winguard rear view mirror with dip and RM610 panasonic cockpit stereo. 

IMG_5415.thumb.PNG.ef690fde03f68cbb49a42ff541bb90f0.PNGI've been doing a bit of research on ABS plastic vacuum forming. Some of the parts on the Esprit were made in this way. It is relatively easy to make a vacuum forming machine. I'm thinking of having a go at making the door corner pieces out of ABS as the originals are damaged and some are missing. I. May also have a go at casting the Aircon knobs out of resin if the normal suppliers can't help. Parts seem to be becoming more of  a problem recently.  Some one needs to start making classic car parts on a large scale using scanners, 3D printers, casting, vacuum forming and CNC machines. We seem to be in the dark ages in the UK compared with the states. Maybe I should give Jay Leno a call. He has his own in house scanning and printing! 

Share this post


Link to post
Share on other sites

I have to rebuild the drive shafts shortly. They seem pretty straight forward. A matter of cleaning then new boots, grease and circlips. My friend put me onto this Redline CV2 grease, seems pretty good!IMG_5395.thumb.PNG.9ddacd5ecc1d32f4b878550dee56c22c.PNG

  • Like 1

Share this post


Link to post
Share on other sites

Thanks Andy great tip! 

Ive just bought some Redline CV2 grease from Deamon Tweeks.

I thought. Get some new cv circlip pliers. Ear type only £8 on eBay.

Might have to service the S1 cv joints whilst I'm at it!

Shortly I will be rebuilding the original  Wastegate with a new diaphragm.I have done some research concerning the blow off valve lubrication. Recommendations vary from no lubrication, copper slip if Nickle grease. A tipurbomrebuild company sells a spray but I can't find out what is in it. Anyone hog any string thoughts on this? 

Share this post


Link to post
Share on other sites

Thanks to PNM engineering I now have a thin gear lever and an Aircon knob. So I now only need 

Aircon panel with the writing DEF, FAN rather than the symbol and

One front wheel lip 15 x 1 Compomotive twenty hole.

quite exciting after two years I nearly have enough to finish this project. 

SKI Racks

I have thought a lot about these. In my view they have to be made of aluminium, the same as modern ski carriers. They will then have a fairing that fits over them to achieve the appearance of the originals. I will start work on these in the next few months. I'm thinking ABS plastic fairings  fitting over the aluminium racks.

Share this post


Link to post
Share on other sites

For those of you new to the Lotus you may not know the RM610E cockpit stereo is too long to fit the roof on the Lotus. In order for it to fit the light part of it is removed and the structure essentially  cut to fit the bulkhead. A nerve racking job and one I'll be attempting very soon! There is a steel structure to cut through under the rubber moulding. You can see how it fits in the earlier picture of the Bond car roof. A  metal bracket grips it to the wood roof moulding at the front and the metal body is shaped to fit the rear bulkhead. A wiring harness fits behind the front trim and goes down the side trim to the footwell area. It's a four speaker system with the main amp in the footwell. The pre amp is built in. IMG_5426.thumb.PNG.5b17d5bb999e2a1b471b44156f3abba8.PNG

  • Like 1
  • Confused 1

Share this post


Link to post
Share on other sites

Good luck with the cutting Fabian! They say measure twice, cut once. I’d measure 10 times and cut once. Been there...done that...

I chose to cut through the plastic accurately with a new surgical knife before using a small hacksaw for the remainder.

 

  • Like 2

Share this post


Link to post
Share on other sites

That's what I did. sharp scalpel for the rubber and hack saw for metal. I actually used the metal chassis as my rear brackets to attach to the bulkhead by bending to right angle and drilling a couple of holes to attach directly to the wood.

  • Like 1

Share this post


Link to post
Share on other sites

Thanks Chaps, I plan to bend the end chassis and measure many many times,. hopefully it should go ok! Just about to order the second leather Hyde for the seats then they are off to Steve Fulcher. He has his dads original seat cutting patterns. He's currently working on my door cards. Can't wait to get it all in. All I need is Carole Bouquet for the perfect picture!IMG_5429.thumb.PNG.f406cd278ecf9d3e6f000c1d99f0a251.PNG

  • Like 1

Share this post


Link to post
Share on other sites

Cry havoc and let slip the dogs of war! I have burnt all the bridges and cut it! Pictures show the front bracket. Metal has been shaped into brackets but because it's so thin I have to stiffen it with the light backing metal case. Will put some pics on when I'm done! IMG_5431.thumb.JPG.593db516c636c165f4547e9f58c6fecd.JPGIMG_5430.thumb.JPG.b1ea336283d6822985bd27b860d6f924.JPGIMG_5433.thumb.JPG.6a7e67c0f98985758fec723e49082835.JPGIMG_5434.thumb.JPG.608063e17b14f32e50b4fe9978e80cba.JPG

Share this post


Link to post
Share on other sites

Finally, its in but has to come out again. The header rail is not strong enough to take the load of the stereo. This means glass fiber reinforcement is needed. In addition I know have to fiberglass the trim piece that fits over the header rail. Lot of work needed to get this tI an acceptable standard.IMG_5441.thumb.JPG.7d5f9414bbaae00e8cbe87a286e16812.JPGIMG_5442.thumb.JPG.891501b66e5a805e9b76f18e3a5016bb.JPGIMG_5444.thumb.JPG.e7ed954f6c371609513d7dc9ada51dce.JPG

  • Like 2

Share this post


Link to post
Share on other sites

I had to modify the end brackets so the bulkhead would fit flush to the end.  They have to be flush with the roof then go through 90 degrees.. I riveted a second panel on to the stick outbbits to give it  more  strength. The stereo is quite heavy and in my opinion there is too much load on the front crossmember. With the windscreen bonded in this increases the strength but even then the header is very thin. The easiest way to reinforce it is with fiberglass paste pressed in the gap and clock detent. I have ordered all the fiberglass materials to refinish the header rail. I will remove the clock part then re gel coat.

Soon I will have another go at the ski racks. It's  a very long process . Firstly styrofoam to craft the shape. Then cover this in glass fiber cloth and use Epoxy resin. Polyester will melt the foam! SO cannot be  USED! The  smooth the Epoxy with West coast Epoxy filler. Once this is done cover it in release agent. Polyester gelcoat and three layers of chopped strand Matt. This produces a mould. Both racks are different so this has to be done twice! Then when the mould is done cast two racks using more polyester. 

I may use the Epoxy rack for a tool and vacuum form abs over it. All an experiment, These racks will only be cosmetic and not structural. All the loads will be taken by the metal structure underneath.

 

Share this post


Link to post
Share on other sites

I'm hoping I have found someone to make the original style Aircon panels. When I have them made exactly the same I will put the supplier on here so anyone who wants one can get one..

  • Like 2

Share this post


Link to post
Share on other sites

Have just been to the NEC classic car show. With renewed enthusiasm I hoping to get this car finished. I am planing, subject to getting a place at the show, to display both of my  Bond S1 and Turbo restoration cars in November next year. If you would like to see the results of over four years and hundreds of hours of work please come along,  no zips or test driving though please! 😀😀

Can anyone recommend a four inch car speaker that is ultra thin - 25 mm or so?

  • Like 1

Share this post


Link to post
Share on other sites

Sounds like a great idea Fabian,  It will be nice for you to show the fruits of your labour and at the same time make a very intresting stand a the show to see, 

Everybody love bond,  Small chance but does madam toswords or however you spell it,  hire out the full size Rodger Moore !    Now that would be fantastic lol. 

Cardboard cut outs will be just as good.  

Or maybe one of those shop manakins dressed up in 80s ski wear like the film wearing skis,  wooly hat and 80s ski googles would cover most of the face anyway.  :)

  • Haha 1

A

Share this post


Link to post
Share on other sites

Spent an enjoyable hour today at PNM engineering checking out their sport 300 race car. I was lucky enough to get a short ride in it from the PNM stall to the main gate a year or so back to save me carrying a manifold about a mile at Brans Hatch! It was real cool. Pete found me an original gear stick thin gear stick. It has been welded so will need bringing back to life for use in my car. There's a circlip at the base which needs to be taken out so you can pull the stick out if the mechanism. 

Does anyone have experience with CNC lathes? I was thinking it should be possible to cut exactly the same gear lever on a lathe?

  • Like 1

Share this post


Link to post
Share on other sites
39 minutes ago, Lotusfab said:

 

Does anyone have experience with CNC lathes? I was thinking it should be possible to cut exactly the same gear lever on a lathe?

Paul at Cranford Eng could probably knock one of those up in 5 minutes.

  • Like 1

Share this post


Link to post
Share on other sites
11 hours ago, 21gg said:

😁 Don't get him started on the outfits! He's had enough issues sourcing car parts! He would be easy to spot though!

Fabian may as well go the full hog as he does with every aspect of his Bond Replicas,,    I am sure changing his name by D poll to Sir Rodger Moore is not far off once the cars are finished,  Just the white G turbo for him to do next lol.


A

Share this post


Link to post
Share on other sites

Well done getting one of the thin gearsticks Fabian - I’ll put my hand up and admit it ewan me that spotted it was missing...... but it’s a must for your restoration👍

  • Like 2

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


×
×
  • Create New...