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Esprit Turbo project car - part3 - the further continuation - Page 178 - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
Lotusfab

Esprit Turbo project car - part3 - the further continuation

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IMG_7374.thumb.JPG.3bb6128ebaf7ca6fb97ad87e69592c20.JPGAre these drain holes or does this bolt to the chasis here? Thanks.

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Upgrade today to remove Google ads and support TLF.

I dont have those on mine. 

The chassis tubes run in the two diagonal raised parts on the rear edge. The panel bangs against the tubes at that point unless you put some rubber boot seal on the edge there.

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I think they are there to drain the depressed section

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Thanks Chaps. With put some rubber on the edge.

Half way through riveting the retainer my rivet gun broke! I dashed to screwfix and bought another, that broke too! I have ordered a Bacho one which looks better quality. The rivets are all in but the tails are not broken off in one side. The new rivet gun arrives today. What a pain! Still this bit is almost done. I had to replace several rivnuts. It does look good under there now! I used a black epoxy boat paint. I'm thinking maybe I should have used raptor coat. You really need a lift for these jobs. Rolling around the floor getting covered in fiberglass dust isn't much fun at my age! 

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Today the flywheel is off to be resurfaced! 

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The  three lugs on the flywheel just knock out. They need to be removed so the wheel can be ground back properly. A simple job for the right engineer! I am replacing the six set screws that hold the pressure plate, as it's good practice. Will post some spigot  bearing pics when I've replaced it. Silly not to as it's an easy job and the bearing is only £7. The spacer made by S and J is an excellent idea. No clutch shaft problems in the future. I have some new heat sheild material for the Turbo heatsheild. I also have a pattern thanks to Steve on here. I replaced the studs on the cam housing, as the ones on there were missing and set screws had been used. The studs allow for spacers. Seems to me there should be two sheild s separated by spacers? Anyone got any pics of the original set up?IMG_7396.thumb.PNG.23de31aeb73031b6bd9b34513a5458e2.PNG

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Rolling around the floor getting covered in fibreglass is no fun at any age.....unless you are of a certain masochistic disposition!

You must be chuffed to be so close to finishing this amazing looking project Fabian.....I'm just hoping to get mine actually roadworthy!   On the subject of which, would you mind commenting on my recent post asking for help on wiper module positioning/fixing?

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The double shield was only on later cars, ours only have the one flat plate. There are spacers under it.

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Unless you've got a time machine I'd estimate longer. Perhaps you can recommission Concorde and fly that around the world a few times?

If you do, please let me know.

Mine has been tuned now and runs well, but still a lot of work to do. Glass and surround trim look great also. Thanks for your input.

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Emergency!

Where are the torque figures for the half shaft retaining bolts, clutch bellhousing( including the four internal nuts? ) cheers. I put it all back together, but as always the Norfolk  boys had the last laugh!

Just need to torque it up before the sealant goes off!IMG_7426.thumb.JPG.7b3aa19ec2812bdcd5b2605e7eb68bc5.JPG

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Can't believe they wrote a manual and didn't include these figures! They must be in there somewhere??

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Well I used a bolt chart for 8.8 grade bolts for generic torque settings/ lubricated threads, so all done! 

Now it's a wait for the clutch parts to arrive. I can then boktvthe engine on and drop it back in. The gearbox used 7 mm and 9 mm threads, very annoying! I replaced all the bolts with new. 

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I used oil resistant permatex after a recommendation to seal the bellhousing and gearbox. The rest of the gearbox is sealed with Loctite 518.

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The engine has landed!

For the first time in some years the engine stand has been dismantled and the engine is on the floor! I was going to replace the spigot bearing with a spacer and a new one. My distrust of new parts is growing. I'm going to check the crank depth first! If the spacer isn't exactly correct, bye bye crankshaft! 

Then the flywheel can go on. With Loctite on the bolts! Still can't believe there are no torque figures for the bellhousing bolts! .

New brake switch fitted to gearbox. Lost my new O ring for the speedo drive! 

I now have an alternator problem. I bought a new bracket and it just doesn't look correct. The belt is rubbing in the mounting bracket. Is the belt long enough? Is the bracket on the correct bolt? This is how the engine came to me! IMG_7460.thumb.JPG.fa0380b7a24f543c2678262299cbd00f.JPG

Doesn't look correct to me! 

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IMG_7460.thumb.JPG.758c588cd15ba96671eaa61d425376e7.JPGShould the end of the alternator bracket go where the red arrow is? Despite how it arrived I think the bracket is in wrong?

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Not long now! Today I will try squeezing bread into the spigot hole to push the bearing out! Then flywheel and clutch fitting. After that wait for new bellhousing bolts to arrive then it's engine back in time!IMG_7462.thumb.PNG.b4f6d2f5c8a4e8be07aa0874fb1fde95.PNG

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@LotusFab

Tim Engle in the US has documented all of the torque figures for the Lotus 907-912 cars. Here are the figures for the Esprit Turbo (1983-1987):

Gearbox  (5 Speed Citroen  --  SM / DS23 and Maserati Merak) Lb-Ft Kg-m N-m Source      
Bell Housing / Clutch Housing                
910 Citroen (Bell Housing)  Clutch Housing to Oil Sump (2 Bolts on btm) 30 4.18 41.0 Gturbo-STurbo, Sec EB, Pg 41  -- Harry Martens Limmen
Citroen (Bell Housing)  Clutch Housing to Gearbox,   7mm 20.3 2.81 27.6 Harry Martens Limmen      
Citroen (Bell Housing)  Clutch Housing to Gearbox,   9mm 28.9 4.00 39.2 Harry Martens Limmen      
907-912 Citroen (Bell Housing)  Clutch Housing to Gearbox, 12mm (dry threads) 36.0 4.98 48.8 Esprit S1 / S2  -- Harry Martens Limmen    
Citroen (Assemble with 12mm Washer under the nuts on the studs)       Parts Manuals -- Harry Martens Limmen    
Driveshaft  (Output Shaft)  Housings,  left and right                
907-912 Driveshaft Housing to Gearbox - 7mm (use Avdelbond A138) 20.3 2.81 27.6 Esprit S1 / S2  -- Harry Martens Limmen    
907-912 Driveshaft Housing to Gearbox - 9mm 28.9 4.00 39.2 Esprit S1 / S2  -- Harry Martens Limmen    
907-912-910 Sleeve Nut Retains Bearing in Driveshaft Housing (F24, F25) 72.0 10.00 98.1 Esprit S1 / S2,  G-Turbo  -- Harry Martens Limmen  
907-912-910
Grub Screw - Locks the Sleeve Nut, above  (Pg F24)(Pg F25) 7.2 1.00 9.8 Harry Martens Limmen      
907-912-910 Bearing Locking Nut, Locks Bearing to Driveshaft  F26,  F25 108 15.00 147.0 Esprit S1 / S2,  G-Turbo  -- Harry Martens Limmen  
907-912-910 Grub Screw - Locks the Bearing Locking Nut, above 7.2 1.00 9.8 Harry Martens Limmen      
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14 hours ago, Lotusfab said:

IMG_7460.thumb.JPG.758c588cd15ba96671eaa61d425376e7.JPGShould the end of the alternator bracket go where the red arrow is? Despite how it arrived I think the bracket is in wrong?

This is my '85 turbo. It has Ac if that makes a difference? Not the best angle I'm afraid. 

rps20190709_104912.jpg

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Thanks Steve, funnily I have just put it on that point and it's perfect. The position above my red arrow. Well I have used up a slice of bread ( hopefully the wife hasn't been counting the slices!) getting the spigot bearing out. You have to have a reasonable seal and hit it quite hard! Easy really and very cheap! IMG_7463.thumb.JPG.c6dbc54b5896c8bd845f55bb8cefbbdf.JPGIMG_7465.thumb.JPG.f2f743c79d59745bf3bfb20c55491ff9.JPGIMG_7466.thumb.JPG.2dafdec305b50243be829a5120df04dd.JPGThe good thing is the bread sticks together and is easy to clean up! The spacer fitted easily with a slight gap and the new spigot bearing flush with letters facing out. Waiting for the N3 grease to arrive. The crank is balanced to the flywheel so it has to go back exactly where you took it off. Easy really with the TDC markings. New spigot in and flush. Something's come up so that's it fir the next week or so. 

Thanks Fridge for the torque settings. They are very similar to those I derived from tables and bolt size.

 The old bread trick has been passed down to me from my grandfather and on through the generations, I was reminded of it whilst watching YouTube - if you believe that you believe anything! 😃😃😃😃😄😄😄😄😄

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I reckon the bread hack would have to be one of the very best!

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Brown bread, the healthy option :)

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It's getting there......

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Borg and beck new clutch. New Nylatron washer, new tprelease bearing.IMG_7475.thumb.JPG.e6824ac319770d098665ccc45b39b013.JPGIMG_7476.thumb.JPG.43472f0ed69a55237e7e32a4392cfcfd.JPGIMG_7477.thumb.JPG.bb236d55b80b0174c93c6f98ac54c0ad.JPGIMG_7480.thumb.JPG.a5ef1ee90657ef388b8addf649ce0092.JPGMobile Urinex N2 grease on most parts.

Mobile Urinex an3 on new spigot bearing, as per the manual. 

Flat bearing to curved fingers on the pressure plate(later design). I've included pictures as they will help anyone else who need to do this. The speedo drive O ring was 1.5 mm x 23 mm. New O ring on inner speedo shaft and new grease in the grease nipple point! 

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Is that definitely the right way round for the fork clips Fabian? I thought the ends might locate into the cut out on the bearing collar. Maybe doesn't make any difference though... 

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