Esprit Turbo project car - part3 - the further continuation

[Lotusfab]

????? 

[Lotusfab]

Is the flying saucer thing a transducer? Does it convert pressure in the fuel system to an electrical signal for the boost gauge? If so it would explain why my boost gauge doesn't move?

Also what is in the tube, fuel or air?

[Choppa]

it's the vacuum reservoir for the heater flap system that direct the airflow in the cabin. The lip of the flying saucer clips under those brackets on the RHS of the photo.  it looks like you'll need to replace the rubber connector as it's split otherwise your heater will stay shut and it won't deliver any hot air when you turn the controls.  

[TAR]

I suspect the wastegate is seized open preventing the turbo making any boost pressure.

So glad you got it running. 

 

[Lotusfab]

Thanks chaps. Well found the heater control then!  Will have to find the transducer for the boost guage and buy some instruments to test the waste-gate operation. There's quite a good article about it on Lotus Esprit World website.I got the workshop manual from eBay on disc, but havnt had time to read it yet.

[TAR]

I dont think you will have a transducer for the boost guage, its mechanical and has a pipe from it to the inlet manifold, if I remember correctly. Bit hazy as I dismantled my car around 7 years ago!

 

[Lotusfab]

Mmmmmm, if it's a pipe that might be problematic! 

[Lotusfab]

Should the boost guage read anything at idle  when just revving the engine?

[Barrykearley]

hmm that's a good one - don't think mine did - only when under load - could be wrong though 

[Lotusfab]

Well have got the car into my garden summer house! Had to get rid of all the stuff that was in there, but I didn't use any of it anyway. There's not much room at all and no heating but should be able to progress the car if the weather holds, as I need to work on it with the doors open.

My plan is to remove the tanks and bring the fuel system online first. The boot boards and tanks externally are very good, but some of the fuel lines are corroded! They will all be replaced. The engine ones on the carbs are all new! They have fitted and extra fuel filter and tied it to the expansion tank, so will remove the extra one and make it factory correct! Why two filters have been fitted I don't know. Maybe they didn't want to get any contaminants into the new carbs? Will clean out the tanks and treat them with the POR tank products which are excellent and have done the job on the S1. 

Am also removing the rear spoiler to remove the tailgate lock. Think I may need a new barrel. There are lots on eBay when I identify which car it was used on, maybe a Rover? 

Then I will sort the gear change and clutch.

first and reverse are difficult. Will have to jcheck all bushes and adjust the cross gate cable. Will then put the trusty borescope into the clutch force area and check ll is correct. The fork seems loose like the pin has dropped off. If it has that would explain the clutch drag. All the parts are new except the slave cylinder. 

Finally will try and sort the turbo. There might be oil leaking into it as It looks like it has been rebuilt. If it hasn't the rebuild kit is £80 and it's a simple job with lots of videos on you tube. Will have to check ll the receipts! Lots of fun ahead!

Thanks Barry, it's all a bit different having a Turbo! Will have to get all the tools and test the wastegate is ok!

[LOTUSMAN33]

Fabian I am with Barry on the boost gauge, you don't normally see pressure until under load.

I will try and remember what the boot lock was from, I replaced one years ago and it was not from Lotus when I bought it.

Dave  

[910Esprit]

7 litres in 5 minutes?! - you need to work out where its going....  as it cant all be 'combusted'.   You won't generally see the boost gauge registering boost without load, unless you are particularly brutal on the throttle.  

Smoke from turbo may or may not be an issue, but with the amount of unburnt fuel sloshing around somewhere, I'd track that down first before worrying too much

[Lotusfab]

All the fuel lines, filters and carbs were empty so they had to fill up, still seems a. Lot of fuel! Unless this car guzzles it down? Although  I did make a ramshackle fuel system for the test. When I have rebuilt it all properly will be able to test it.

There  seems to be. The same problem on here will the Turbo as the S1, not enough pictures of the bits! Will try and change that with this blog, so pictures coming soon! Found the original locknut for the wheels in a box I got with the car. The Anodising has started to ware. Still can believe how complete every thing is. The service book has all stamps from Bell and Coville who supplied the car right up to 60,000 miles. There are wads of receipts too. It's now reading 60600! Thousands have been spent on engine parts with PMN! Sounds quite sweet when it's going. Just the issues mentioned above to sort. Am having second thought about turning it into the Bond car. Havnt ever seen anything so complete in this condition  34 years old! The worst thing about it is the paint on the rear spoiler. Somebody did a shoddy job on it!

[Barrykearley]

Haha - 7 litres - that must be just the link pipe between the tanks......

Sell me the old dog Fabian 

[Lotusfab]

You never know!

[Lotusfab]

Just ordered the first new bolts. This time I have a sheet and will try and record all of the sizes.

The rear upper spoiler = 5mm x 25 MM.

these use 25 MM penny washers that are cut off, to hold the upper rear spoiler on.

the clutch slave Cylindar is a Girling, similar to the Landover. The Slave repair kit I believe  is SP2029. Will tell you if it fits! 

Have just spent ages trying to get these rusted bolts from inside the boot. Need to get the spoiler off to get the tailgate lock out and find out what car it's off and check the key barrel. Two more to go but my motivation failed me. They are waiting quietly rotting until tomorrow, when I will get my revenge! Standby for the next exciting instalment! ????

[silverfrost]

Awesome news fabian,  don't talk to me about rust, looked at the s2 headlamp motor brackets on mine today after noticing 2 rusty scabs on the floor only to find the tin worms have eaten the bloody things ! Good job I am fitting alloy ones with mx5 motors lol.

Great to see this project gathering pace mate. 

 

[Lotusfab]

Spoiler Off! Dreaded rivnuts hold the spoiler on, that's why they failed and were very difficult to remove. Rubber strip between the spoiler and body. Lock removed, no markings on it. No way I can see of removing the barrel as it seized solid! Think it might be a BL lock. Have to keep searching eBay unless someone out there recognises it? May have to invest in a blast cabinet to remove all the corrosion.

[Stuart Monument]

Hi Fabian,

 

When you discover what lock it is would you mind letting me know as I also need one. Of course if I find out first then I will let you know.

You seem to making faster progress than me. Keep up the good work

 

Stuart

 

 

 

 

[ChrisJ]

Austin Princess looks close

 

[Lotusfab]

Mmmmm, the key code from the build card was British Leyland, so must be something like that?

this I think is the marina rover key. It's the wrong key and the lock is too small.

[Lotusfab]

Bottom picture shows the Rivnut holes and the foam tape.

[Lotusfab]

Anyone with a turbo and original keys on here? If so can they confirm if the door keys also do the boot or is the boot key the same shape as the ignition key? The build car suggests the latter, but with Lotus records it could be wrong???

[ChrisJ]

Door key is completely different.

Ignition key is the same shape, but a different key. I used to differentiate with a blob of tipex on the ignition key

 

[Lotusfab]

Then the build card is correct it's a British Leyland key. Now need to trace the lock! Start with all BL cars from that time.