stevetsl Posted February 20, 2017 Author Report Share Posted February 20, 2017 Hi All By now I should have been posting pictures of the new flywheel and adaptor plate, however due to a design cock up I now have a very pretty by totally useless flywheel. The Lotus clutch mounts with 6 bolts and my new flywheel has 8 bolt holes, the design is such that it can`t be modified, hey ho, all part of the joys of engine conversions its just put me back a couple of weeks while I get more material and start again. In the meantime I have been rebuilding the rear suspension so rather than the engine parts here are a few pics of before during and after the suspension work, hope to be back in a couple of weeks with the flywheel and adaptor photos. Quote Link to comment Share on other sites More sharing options...
silverfrost Posted February 20, 2017 Report Share Posted February 20, 2017 Gutted for you Steve, and sorry to hear the flywheel cant be saved, but you sound like your taking it on the chin fair play to you, and looks like your keeping yourself busy though, top job on the rear suspension, Started doing mine a while ago but that bottom stud is wanting to stay where it is on mine, is rusted to hell ! Look forward to seeing this conversion progress Quote A Link to comment Share on other sites More sharing options...
Gold FFM Escape Posted February 21, 2017 Gold FFM Report Share Posted February 21, 2017 If the engine conversion turns out as good as the rear axle rebuild, it will be well worth the wait! 1 Quote I have made many mistakes in my life. Buying a multiple Lotus is not one of them. Link to comment Share on other sites More sharing options...
stevetsl Posted February 21, 2017 Author Report Share Posted February 21, 2017 Thanks for the comments guys, here is a scrap flywheel ! Quote Link to comment Share on other sites More sharing options...
Steve4012 Posted February 22, 2017 Report Share Posted February 22, 2017 Suspension looks great. Is that new shocks and springs and refurb of the rest of the parts or all new? Quote Link to comment Share on other sites More sharing options...
stevetsl Posted February 22, 2017 Author Report Share Posted February 22, 2017 New shocks, existing spring checked, shotblasted and powder coated, all other parts shotblasted primed and painted, all new bushes and bearings. Working my way from back to front, will do the same at the front when I get there ! its the engine and transmission conversion which is taking the time. Quote Link to comment Share on other sites More sharing options...
hilly Posted February 22, 2017 Report Share Posted February 22, 2017 Oooooooh cool, another engine conversion ☺ Looking good so far. It will be interesting to see how this one pans out given it is 10 years since Punky did his. 30 minutes ago, stevetsl said: its the engine and transmission conversion which is taking the time. You are not wrong with that statement......... Hilly Quote 1981 S3 4.2 V8 6 speed (The Mutant) Mutant V8 Conversion Thread Knowledge is power .................... apparently. Link to comment Share on other sites More sharing options...
silverfrost Posted February 23, 2017 Report Share Posted February 23, 2017 Ah ! Hilly welcome back mate pop over to the introductions and introduce yourself lol Quote A Link to comment Share on other sites More sharing options...
stevetsl Posted February 27, 2017 Author Report Share Posted February 27, 2017 Not what you really want to find when restoring the suspension, luckily I have found and have a used replacement on its way. Interesting that the crack is exactly in line with the gap in the split bush. Don`t know if it was like this when I bought the car or whether I caused it when taking the suspension apart but it came off ok without any force required, Quote Link to comment Share on other sites More sharing options...
Gold FFM Barrykearley Posted February 27, 2017 Gold FFM Report Share Posted February 27, 2017 Doh Quote Only here once Link to comment Share on other sites More sharing options...
silverfrost Posted February 28, 2017 Report Share Posted February 28, 2017 That is sxxte news Steve, Gutted for you, but on a bonus note if it was done before at least you have spotted it, could of been far worse while doing some spirited driving with the new engine ! This is also why some people x ray them as hairline cracks can form and will only get worse given time and just fail all a sudden. They are not that hard to get hold of and can still be purchased new from sj or secondhand but sadly not the cheapest bit on the car. Was your car the barn find restoration project from wales that was for up for sale last year ? Quote A Link to comment Share on other sites More sharing options...
stevetsl Posted February 28, 2017 Author Report Share Posted February 28, 2017 Yes it is the Welsh car, I have heard there is some history attached to it but have not yet found out what it is, the car has had a stack of previous owners and it seems to have changed hands on a regular basis. I am not over bothered about its history as when I have finished the restoration and modifications it will be a different car. I spoke to SJ about a new bearing carrier to be told they are now obsolete but have picked up a secondhand part from LotusBits. I think I am keeping the various suppliers in business at the moment ! 1 Quote Link to comment Share on other sites More sharing options...
jonwat Posted February 28, 2017 Report Share Posted February 28, 2017 A good aluminium welder would restore that no problem. Quote Cheers, John W http://jonwatkins.co.uk Link to comment Share on other sites More sharing options...
silverfrost Posted February 28, 2017 Report Share Posted February 28, 2017 Steve, Yes nothing wrong with plenty of past owners, or history, All our cars are old and have various pasts some good some bad , I thought it was the welsh car as i could see plenty red over spray on the rear radius arms Glad this car found a good home, a few of us on here had concerns it would be purchased by someone and sold as bits, but its safe now. SJ still lists them on his site, so not sure why he has not taken them off he cant get hold of them, Also very worrying as Lotusbits supply is also running down as Mike is not buying up many esprits to part out as they are getting thinner on the ground. I am after both rear ones but for a stevens car, not sure how low on the ground these are used but will keep my fingers crossed. ! I just hope Steve or Mike looks into getting new ones cast at some point Quote A Link to comment Share on other sites More sharing options...
Popular Post stevetsl Posted February 28, 2017 Author Popular Post Report Share Posted February 28, 2017 Hi Dan Hope you get sorted with some hubs for yours, I have access to very good 3D modelling, casting and machining facilities, if there was enough interest I could look at producing some of these. I have a theory on my failed hub, if there is any corrosion at all between the bottom wishbone bolt and the split steel bush then the expansion due to the corrosion will cause the bush to expand into and stress the aluminium, the point at which most expansion will take place is at the split in the steel bush. In my hub the split in the bush is aligned with the thinnest section of aluminium and the split in the aluminium is directly above the split in the steel bush. If the steel bush was turned through 180 ° in the casting the split would then be next to a more meaty ( stronger ) section of casting. I have checked both the other side of the car and the second hand replacement casting and in both of them the split in the steel bush is lined up with the stronger section of the casting. Any thoughts ? is this something we should be checking on the cars, presumably as they get older the hidden corrosion between the parts could be what is causing the cracks in the aluminium castings 3 Quote Link to comment Share on other sites More sharing options...
Gold FFM Barrykearley Posted February 28, 2017 Gold FFM Report Share Posted February 28, 2017 That's a good theory. Bit like the damage water turning to ice can do Quote Only here once Link to comment Share on other sites More sharing options...
silverfrost Posted February 28, 2017 Report Share Posted February 28, 2017 Sounds like a good theory, Thankfully i am in no desperate rush for the hubs as i have a decent set for the project, well hopefully still need to get the bottom bolt out of of each of them, so will not count my chickens yet ! The stevens hubs are for another project as those hubs make the wheel offset a hell of a lot more pos, other wise i would end up with deep dish wheels like a barrel. I had thought about the casting myself, and know a few folks who work at a decent foundry, they have a machine that you just chuck the part in and it uses dust and glue to make a master mould and them it just replicates it, You would obviously have to add mass to the machined areas though and then die grind off afterwards before the precision machining. Downside is that place is so high tech now and run so well, chances of the lads slipping stuff in these days is a no go, its like camera city. Would be worth you looking into though Steve as at some point none will be left, and i would hate to see the bill for getting one of these cnc machined from a block of raw alloy ! Quote A Link to comment Share on other sites More sharing options...
910Esprit Posted February 28, 2017 Report Share Posted February 28, 2017 Not a typical fallure, although there are many seized studs in those lower links. Was it the nearside rear? I recall that car appeared to have had a repair to that rear quarter. Maybe taken a knock? I think some of that red overspray made it as far as shropshire! 1 Quote Link to comment Share on other sites More sharing options...
stevetsl Posted March 1, 2017 Author Report Share Posted March 1, 2017 Nearside seems ok, failed part is the offside, not seen any evidence of past damage at the rear, has been a small repair to front near side. Whoever painted is was quite generous with the paint, it is everywhere ! Quote Link to comment Share on other sites More sharing options...
silverfrost Posted March 1, 2017 Report Share Posted March 1, 2017 I think Steve if you look on the nearside rear inside the engine bay area on yours it has had some glass fibre repair work done around the area of the rear of the wheel well hump., I think that is why 910esprit asked about the nearside as when your car was up for sale on ebay and other sites a photo showed up showing a repair. Quote A Link to comment Share on other sites More sharing options...
stevetsl Posted March 1, 2017 Author Report Share Posted March 1, 2017 will take a look and let you know Quote Link to comment Share on other sites More sharing options...
stevetsl Posted March 28, 2017 Author Report Share Posted March 28, 2017 At last here is the engine / gearbox adaptor plate and flywheel ( made correctly this time ) The clutch assembly is all turbo esprit. Should have the engine and box mated together this weekend and can then start to make some proper progress. Next up will be the engine mountings, alternator mounting and exhaust system, in and among I am now rebuilding the front suspension and brakes, should have some pretty pics of that soon. 1 Quote Link to comment Share on other sites More sharing options...
silverfrost Posted March 29, 2017 Report Share Posted March 29, 2017 Awesome Steve, glad you finally got all the bits back and thank fully correct this time Really looking forward to seeing you get this motor back on the road it deserves it Quote A Link to comment Share on other sites More sharing options...
Popular Post stevetsl Posted April 17, 2017 Author Popular Post Report Share Posted April 17, 2017 Happy Easter to all Things have moved on a bit, all the suspension now rebuilt and back on the car, brakes overhauled and all braided lines fitted. Engine and box now mated together and sat in the chassis I bought to use as a jig, engine mounting and alternator next up, I can see already there will be an issue with the gear linkage, will need to be a bit creative here. Starting next on the cooling system refurb, will get the standard radiator checked over and maybe recored 3 Quote Link to comment Share on other sites More sharing options...
cor Posted April 17, 2017 Report Share Posted April 17, 2017 Steve, well done, love the half chassis you have as a mock up! this way you have all the room to figure out what to do with the components. myself i am using a chassis i lent from escape to do these jobs. can you use the headers and inlet manifold of the duratec or do you have to make your own? Quote Link to comment Share on other sites More sharing options...
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