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Esprit Turbo project car - part3 - the further continuation - Page 182 - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
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Esprit Turbo project car - part3 - the further continuation

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Well I have extensively cleaned and polished the shaft. It still has a resistance. On closer inspection the bellcrank is missing a washer and applying pressure to the crossshaft when it's at full travel! Should have this sorted very soon!

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Anyone know the routing of the speedo and handbrake cables?

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Looking good Fabian - look forward to seeing some proper photos out of the garage when you’re all done😎

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Well a good day's work, until I got to the calipers! New brake discs. The calipers foul the disc. I guessing the shims have to be used behind the disc to shim it to the centrr. You can see the caliper is rubbing against the disc! Has anyone else had to shim them? 

IMG_7801.JPG

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Yes they do need to be shimmed to centre the disc. Were there no shims in there before?

Or, there seems to be something on the other side, are you sure you have not put the shims on the wrong side of the disc?

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Yep I put the shims on the side of the driveshaft adapter, It looked like that in the manual. I will have to dismantled and do it again!

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They have to be moved to each side as required, maybe only one needs moving.

Checked mine and there are none on the driveshaft side though.

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Thanks. Have you got rid of the brake hose to short coper pipe to caliper and just used a longer stainless hose eliminating the copper pipe part? 

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Ok offside caliper done with shims on inside of disc, seems to work! Just need to move the shims on the near side. Decided to keep it stock and get PNM to make me some small copper hoses. About a day to get the brakes online now and the driveshafts in. Then torque it all up. I lost the Turbo boost pipe sleeve nut. Once I have that I can complete the Turbo install fit the new stainless exhaust and heat shielding. I'm expecting trouble with the exhaust fit so may have to have it adjusted. Then just the plenum, air intakes and top fuel hoses to bolt on! Soon, the engine start test with a fire extinguisher on hand, I will be installing a fire extinguishing system in the engine bay eventually - just in case! . IMG_7809.thumb.JPG.a9b118f9c6c5027640349e86e4042905.JPGIMG_7811.thumb.JPG.f02ff4eb724f614644e7f6e6586695db.JPG

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your spring is not sitting in the damper correctly Fabian

 

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Thanks Phil I'll take a look at that! 

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On 13/08/2019 at 04:37, PhilW said:

your spring is not sitting in the damper correctly Fabian

 

Did you resolve the gearbox issue? 

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http://turbo-specialist.co.uk/

Heres the people who sorted my Turbo, excellent prices. I know someone else who has used them. Their Renault Turbo had disintegrated. They did the whole job for 1/8 of the main dealer price. Car runs really well! Although a fairly new company they do very good work. If your in Surrey and need a good job at a reasonable price you could do far worse than use  these people. They are fair and do what they say.

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Nuts! IMG_7821.thumb.PNG.f1b0b663500dcb64c49a3ada71d1adeb.PNG

Changing the subject when your rebuilding the chasis and you find some bolts and hub threads arn't long enough to get the nylock nuts on past the thread the reason is the Lotus Nyloc nuts are reduced width! Fortunately you can buy new ones from S and J sports cars.

I should have the throttle connected and the brakes back online within the next few years days. (Oh and the bring back in- thanks Phil!). I fitted a new high torque starter motor. The problem is the brown alternator wire is no longer long enough to reach from the alternator tomthe starter connection! There's always something!

I bought a new ignition harness. It's for a later car and plugs into the main harness. Seems a shame to modify it as my car only use about two wires from it and the plug connector! Oh well, you have to brake eggs to make an omelette! 

Tantalisingly close to main engine start. I all goes to plan I should have this alll running with skis on buy the end of September! Can't wait to test it after three years of research and hard work. I may have to treat myself to a 1981 Casio watch AkA FYEO! I'd prefer a signature on the car from Carole Bouquet, if any of her mates are reading this! IMG_4419.thumb.PNG.cae9b4209fd55d01065cef709fc51ace.PNG

Just been reading Mr Bond was 54 when he got his hands on this, at 52 I think I've upstaged him!

Oh and note in the picture the skis do not have a metal support bracket at the lower ski mount. This was probably added after the lower mounts cracked! 

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Chassis and engine bay look stunning Fabian,  will be a shame to get it dirty ! 

Do not worry you will soon be Mr Bond,    Will keep my fingers crossed for you it snows in the winter months in Blighty,  so you properly look the part lol.

Keep up the great work,  keeping my fingers and toes crossed for you also on the engine start chap.

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A

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If it's does snow there are going to be some adverse comments when they see my Skis! The big question is did they cut the scene so Mr Bond could take those shoes off. Can't see how he could have driven the car with them on!

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Well this car won't give up easily! I refurbed both calipers. After three hours and about 10 removals and installations of the rear caliper trying to get the handbrake to work I took it apart. I tested the splines in the mechanism and discovered they are worn out! 😡😡😡

So what now? I need to source a new ratchet mechanism or new/ used caliper. Anyone got a rear Near side/ left one they want to sell?

Drive shafts

What an effort to get these installed. Only one in so far. Despite all new bolts and a total rebuild they won't slotbon very easily. You have to pivot both ends. I suggest bolting the hub end on first then lowering in the other side from above. My hands and fingers feel like they are falling off after hours of faffing with this. One more to😫😫😫😫😫 do! 

This side is complete now.IMG_7825.thumb.JPG.380efab0f19e54e1ebf60b074ab5fed8.JPG

Oh apart from the brake hose! 

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Ok how do the rear calipers work? Ratchet does the handbrake. Rotate the piston 45 degrees from the install position to disengage ratchet and pull piston out. The slots in the piston align with the bulge on the pad back for the ratchet to engage. I have a new piston which the previous owner bought. Is it the correct one? The teeth don't look correct to me, but then I havn't seen a correct one! Either these teeth are worn or the ones in thevother end are worn out.IMG_7827.thumb.JPG.e2a33925df9652be1c81af6afce2e407.JPGIMG_7826.thumb.JPG.185860c528d1e98eb76d4659416e55a2.JPG

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Probably need better CU photos of the rachet parts to assess.

They do wear, especially if badly maintained or assembled.

Callipers are very hard to find.

Edited by Fridge

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The piston is probably correct. I would say the left partvis worn out. Bad news! 

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