The Rebuild - 1983 Turbo Esprit

[trackmagic]

Hello all,

Introduction:

I have owned my Lotus jusr over a year and love it. I have always grown up around British cars due to my Dad's influence. He is a Europa man, which are cool, but I think once you go Esprit you don't want to go back. I have always wanted an Esprit and when I sold my Formula Ford this car became available. I am technically the third owner although the second never registered it (only had it 3 months- divorce). Like many of these cars it was good cosmetically but needed some mechanical help. I like working on my own stuff and it took awhile to get this thing up to par. What was shocking is that all the work was done by LOTUS EXPERTS (or so was claimed). The amount of hap hazard stuff was not very encouraging. Nothing serious but you know what I mean.

The cam towers had a leak and I was all about doing that when it occured to me that I was better off pulling the engine. Well one thing to another and now the engine is in pieces. Good news is that I am glad I did. Seems like this thing had an overheat issue at one time and one of the pistons was scored and someone took a scotch brite wheel to the deck of the block. It was also a time for me to put in the forged pistons.

Also I have the good fortune of having my friend Bob Slade assist me on the rebuild. Bob builds a good majority of Cosworth DFV' s for the vintage F1 racers. So with his gudance I am looking forward to having a well tuned engine to install.

I will include info on what else I find as well as try to include lots of photos. Here are a few to start.

Jeff

[slade]

...that sounds something special

Good to see another black G car with gold rims B)

Good luck with all that... Looking forward to seeing more, but I'm afraid that's probably as much help as I can be with all this, heh. Whereabouts are you in ca? (BTW. I'm totally not related to Bob Slade, I don't think )

Edited May 14, 2007 by slade

[t70]

hmmmm. I think that the two pictures should go together... ford cosworth v8 in a lotus... very nice!!!....

[trackmagic]

I am up in Northern California (salinas). If you are from New Zealand than you might be related!

Thanks,

Jeff

[USAndretti42]

Nice looking car, Jeff. If your engine is too bad, Paul in Camarillo can get you a newer one for not too much now his car is scrap. I don't know if you've been following his thread.

If you're in Salinas, I suppose you will be running it round Laguna Seca when it's done. Or, if not, taking it off to Big Sur which is not too far away. Plenty to look forward to.

[trackmagic]

Haven't seen the thread but thanks for bringing it to my attention. Yes that engine would make a nice upgrade for what I eventually want to do. Almost assured that it will be totalled and would be interested in buying it.

I am familiar with Laguna, I have about 25,000 laps around that place. Lucky me my day job is a instructor for Skip Barber. You are also right about HWY 1, nothing better than to zip down to Big Sur in the Lotus. She will be up and going soon and hopefully will make it to Aspen.

Thanks,

Jeff

[lwasson]

Hi Jeff

I restored my 83 Turbo for the chassis up. Good luck on your project and if you make it to Aspen I'll show you my picture book of the rebuild.

Louis

'83 Turbo

[paulbutvila]

I'ts cool that you have someone so experienced to work on your engine. Unfortunately I don't have that where I am in Kelowna B.C. Canada. We do however have our share of "butchers" who are will ing to "give it a shot"...NOT! Godd luck with your build and by all means post pictures. These are great cars to own, despite what some people say about them.

[trackmagic]

More pictures to come. ................. Right now just getting in all the parts. JE pistons unfortunately sent me the wrong size units so waiting on new ones to show up. Going to go .010 over as they can be power honed to size. Just finished the valves and installed new exhaust guides. Rebuilding the turbo and wastegate. Wastegate had the nut that holds the valve to the diaphram come off and so was just floating around. The "lock nut" was of the wrong type (nylon) and that was the cause. Replaced the guide and will reface the seat. Exhaust manifold was coated inside and out and looks good. Carbs are rebuilt. Block welded to fix corrosion.

Need to fit pistons, deck block and head.

Keep you posted.

Jeff

P.S. Head had been off before and someone used a scotch brite wheel to do gaket clean up. Bad idea as this ate into the aluminum and so hence the decking.

[f1karting]

Hi Jeff

I restored my 83 Turbo for the chassis up. Good luck on your project and if you make it to Aspen I'll show you my picture book of the rebuild.

Louis

'83 Turbo

Hi Louis.. how the car? Just about done my 85... 84 still half done..lots of parts molds tho' Jan

[psychotronik]

Wish I had been using this forum sooner! (first post)

So cool to see other nutters out there.

I've been trying to finish putting my former basket-case '83 turbo back together for a few years. Finally getting close.

Good luck with yours, and keep us up to date.

Edited July 7, 2007 by psychotronik

[lwasson]

Hi Louis.. how the car? Just about done my 85... 84 still half done..lots of parts molds tho' Jan

Hi Jan

Been meaning to email to say hi and see how the rebuild is going. How's the other Esprit? Did you keep it?

I just noticed your reply is dated June 17....sorry for the late reply.

Taking the Esprit to Birmingham Motorsports Park this coming weekend to hang out with other Loti owners and enjoy some Cam Am racing.

Thought about driving the Esprit to LOG27 but that's 22 hours in the seat. Don't think my butt can handle that. So we'll fly.

Can't wait to see your all your mods on the '83.

Louis

'83 Turbo

[trackmagic]

Been awhile since my last post but progress has been slow. Got down to checking clearances in the main bearings and found them to be too much. In checking the bearing bores found a slight twist in the main bearing pan. Made new dowels but the bores still out of spec. Priced out oversized mains and the quote was $500.00 plus the cost of boring. Decided to deck the pan .011 and have the mains bored and keep the standard bearings. Going to deliver the block up to Phil Rielly to have the work done.

Other than that did get the head assembled and had my machine shop friend O-ring the cam cover towers. This should cure any leaking forever. Need to do the same on the cam covers. Did locate a chargecooler and so now to plumb in a radiator. Oil lines are being replaced. Decided on re-using the fittings by cutting off the swedged sleeves and going back with Oeteker clamps and Aeroquip hose.

Oversized pistons have been honed to size and rotating parts balanced. Once block return we should be able to start bolting it together. I have been working on a web site for my project with a photos page for work beeing done.

Photos http://web.mac.com/trackmagic/iWeb/turbo%2...rit/Photos.html

Jeff

[cly_mitchell]

Keep up the good work bro.

Cheers,

Clay

[trackmagic]

Some very cool cars at Phil Reilly's awaiting work.

Jeff

[yeller77]

Oooh, TZ!

Nice work, Jeff, keep the pics coming!

Eric

[t70]

OMG... I wish I had a shop that clean and nice!! WOW!!

[trackmagic]

The latest in delays.

The main bearing bores didn't clean up as we would have liked and so having to go to oversized was needed. Right now waiting on word if they are all available from the factory and just how long I will need to wait.

Jeff

www.esprittubo.com

[trackmagic]

Progress in the "two steps forward and one step back" going according to plan. For anyone having or thinking of going down this path my hat is off to you. I can't say anything has gone "to plan". Just about everything has needed some attention. From parts to fit. Once the bearings arrived to process of assembly began. I did opt for the Dave bean upgraded timing belt. This is the rounded belt with adjustable cam pulleys. I am installing a chargecooler so we are having to make some ports for the carbs. Here are some pics. Still need to source out a heat exchanger but think I am close.

[DanR]

Stop and fit that black engine against the wall instead!!!

[trackmagic]

Thought has crossed my mind on many occasions! 500hp @10,000 RPM would be the ultimate. $$$$$$$$$$$

Jeff

[kyliesmith.com]

Wow......... your motor looks amazing, I love seeing these threads. Hats off to you

[trackmagic]

Time to mock-up the chargecooler. One bracket will have to be fabricated because the later design incorporated the mount to the cam cover. Also new pressure tubes for the carbs will need to added. New electric Bosch pump arrived today. Still need to order up the heat exchanger and then do the plumbing of lines.

[trackmagic]

Been awhile since my last update. Most of my time spent has been getting the car ready for the engine to go back in. Replaced choke cable, new oil cooler lines, added lines for the chargecooler, lots of cleaning, replacing heat insulation and the list goes on. Bell Intercoolers built a real nice heat exchanger. Looking forward to getting that part done. Here are some pictures of what has been done. Hoping to get the engine installed by next week.

Also been reading up on oils and the changes that are being made concerning ZINC additives. This one product is causing major headaches for older engines that depend on it. Newer formulations are getting rid of the zinc because of potential harm to catalytic converters and oxygen sensors. Makes sense to start checking if your favorite oil is going to be effective. I plan on running a "break in" oil (www.joegibbsracingoil.com) with a high ZINC content and then switch to a full synthetic like Redline or Silkolene. For the transmission it looks like Redline MT-90.

Cheers,

Jeff

[Simon350S]

Very nice mate.....

one day.... oh one day mine will be almost as pretty.....

Simon