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S3 TURBO Chassis restoration ( factory Fresh ) - Esprit 'Project & Restoration' Room - The Lotus Forums #ForTheOwners Jump to content


S3 TURBO Chassis restoration ( factory Fresh )


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PART 2.......  After its 450' dip and soak  in molten zinc  it slowly reappears clean and just like new..   But the process has a bit more to do . The next step is into a passivate  bath to

After I did the S300 restoration a few years ago quite a few asked questions about procedures I used to get that just like new factory fresh finish..  Well I have a customers 1982 S3 Turbo chassis to

....and now reunited with its body. Happy days!      

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Fantastic work Dave....as always!

Looking forward to getting my hands on it and fitting the shiny new suspension. 

A millimetre perfect chassis. What a starting point! 

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25 minutes ago, RichardJGC said:

Fantastic work Dave....as always!

Looking forward to getting my hands on it and fitting the shiny new suspension. 

A millimetre perfect chassis. What a starting point! 

C’mon Richard we really need to see some pics of progress as you go😎

 

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8 hours ago, RichardJGC said:

Fantastic work Dave....as always!

Looking forward to getting my hands on it and fitting the shiny new suspension. 

A millimetre perfect chassis. What a starting point! 

Nothing like a nice clean / straight starting point to build from..    Plus the peace on mind it has been done correctly not bodged to just look good , This will now last at least another 40 years....   Especially with the new brake pipe mounts to stop a repetition of the bi metal corrosion that took place.  

I will contact soon to arrange suitable delivery date..

Dave ( in this case only very slight Changes)    

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39 minutes ago, 910Esprit said:

How was the chassis rail that runs by the manifold.  Do you treat this any different or just get it clean?

On this particular chassis , other than zinc depletion ,there was no damage at all ..  A fairly straight forward procedure.  However there are many where the Zinc has burnt off and rust and even rot has set in.    This presents a different set of problems..  Even with just rust pitting the integrity of the section has been compromised..  Most owners look at the outside and assume that is it. Unfortunately the same applies to the inside..  For those that have this issue, they should use an endoscope to inspect the inside , they may be surprised .  On the ones that have rotted through , it is clear to see that a great deal of the corrosion has come from the inside as well ...  So in those cases, on a chassis I would be doing the above procedure on , I would set the chassis in a jig . remove the offending section and replace with a new piece of the same specification..   This would give the chassis its full integrity and once re-galvanized would be completely invisible.. good as new again...       

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Yes....coming soon to a garage near me. 

Think i will just set up a chair in the garage and stare at it for the first day! Its a work of art. 

Lots of frantic sorting of plating and powder coating batches going on now. It certainly focusses the mind! 

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Hi Dave,

Great write up by the way!

I am just in the process of repairing an s2 chassis.

I would love to go down the galvanisation route. Is there any reason that you could think of; why I couldn't galvanise a previously un-galvanised chassis, and would you think it necessary to drill venting holes etc. in preparation?

Would appreciate your help on this.

Cheers

Mark

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Hi Mark, 

Absolutely no reason why a previously un-galvanized chassis can not be prepared and done.   As you say the drain and vent holes need doing, this can be done by you or left to the specialist as long as they are well versed..  I personally would do yourself and ask them to check as well..    (Use previously galved chassis info as a guide for drilling etc.) 

It would in this case be well worth a comprehensive media blasting first , with emphasis on any enclosed sections...  Also as the chassis will have years of weathering and paint in enclosed area's that media blasting can not fully access , can i suggest chemical/costic dip to make sure all surface impurities are expelled..  Also ask the Galvanizers to allow a little extra time in the acid process to eat out any tiny corroded points on said closed of areas unseen which media blast will not have removed. 

As long as the chassis is in good order once fully prepared properly there is no reason why your end product should not look as the one featured above.. 

D      

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On ‎16‎/‎05‎/‎2018 at 21:15, CHANGES said:

All datum points are spot on or within 0.5mm

Interested to know how this check is done? I would like to be sure that our chassis is ok.

 

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3 hours ago, NR2k said:

Interested to know how this check is done? I would like to be sure that our chassis is ok.

 

I use Chief jig frame alignment measuring bars..   They are old hat buy today's standards but very accurate in the right hands. 

However you can get a fairly accurate assessment of you chassis alignment yourself buy using two people and a quality steel tape.. You measure the various datum points and compare to factory spec..  The biggest tell tail is the diagonals. if a pair of these are out then the rest generally follow.. ..   on the later chassis the factor spec allows up to 5mm.on these , but you don't often see them that far out unless after a shunt.   If your Esprit tracked up well prior to stripping with no noticeable lay back on the wheels then you will have little to be concerned with..        

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  • 3 weeks later...

Just read through this Dave, Great right up and cheers for posting. 

Fantastic finish and also hope for lots of folks with early S1 and S2 cars to get this done. 

Hopefully you can gigi Mike at Lotusbits.com the nudge to get his elite and eclat ungalvanized pile done :thumbup:

What would be the cost to pop an esprit chassis on you jig for spec check ?

 

 

 

A

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  • 2 weeks later...

Looks like you may of started a trend Dave ,  

Everyone will now want a new shiny looking chassis during their restoration rather than chassis paint finish ! 

A

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On 16/05/2018 at 21:52, CHANGES said:

 The post dimension check is what most seem to be concerned with...

 

Yes yes! we need to know how to do that! Pretty please Dave, my chassis is in a heap 🤓

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How much are we talking to get a chassis re galvanised? Just asking you understand, nothing to do with the Turbo project sitting in my garage...

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Not worth starting anything now...🍺

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  • 2 years later...

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