Europa TCS chassis repairs

[europaspecial73]

Hello!

I have a 1973 Europa Special with 365 transmission that will need a new front T-section due to rust and cracks. I have tried to find dimensions/drawings for the chassis with 365 transmission with no results. Does anyone have similiar dimensions for the TCS chassis that are shown in picture 1 for the S2 chassis?

One thing I noticed when searching through the internet was the angle between the main chassis and the front T-section. ”S2 chassis drawing” by Eddie Kirby from Lotus Europa Central (picture 2) shows that there is a 3 degree angle between the main frame and the front T-section. Any idea whether or not the angle is same in the TCS chassis?

When inspecting the current chassis I also noticed that the bottom end of the T-section seems to be a bit wider than the top (picture 3, Y being wider than X). Should it be like that or is it due to the rust, distortion and previous repairs of the T-section? Any dimensions for this would also be appreciated.

[4129R]

Where in the World are you?

I have 3 bodyshells off their chassis, so I can help with dimensions.

[europaspecial73]

I live in Finland so I guess we'll have to continue communicating via this forum.

It would be awesome if you could provide the angle between main frame and T-section, dimensions 8, 9 and 10 in picture 1, X and Y in picture 3 and the distance between body to chassis mounting points below the dashboard and front T-section (shown in the attachment.) 

Thank you very much for your help! 

[4129R]

Dimension X is 95mm.

Dimension Y is 105mm

The suspension tubes welded into the box section are definitely at an angle.

They are 10mm out of vertical, so if  I put a 10mm spacer in at the top tube, they are vertical.
I think the 10mm measurement is easier to manufacture/adjust.

[europaspecial73]

Hello and thank you for the dimensions.

Do you have dimensions 8, 9 and 10 in picture 1 and the distance between body to chassis mounting points below the dashboard and front T-section?

[4129R]

I just took the chassis in to the garage for welding so it will be a week or so before I can make those measurements.

[europaspecial73]

Any update on the measurements or is the chassis still at the garage?

[4129R]

Chassis back.

I will try to remember to measure tomorrow.

We have been 55 days without rain, and 32'c for many days, with thunder and floods and a full lunar eclipse forecast for tonight.

I am also expecting 4 horsemen to ride by signalling the end !

I hear Scandinavia has been melting too with 30'C in the Arctic Circle.

P.S.

Chassis just measured before the apocalypse.

All dimensions centre of 1/2" bolt to centre of 1/2" stud.

8 =639mm
9 = 788mm
10=221mm

[europaspecial73]

Thank you very much for your trouble!

[vito84]

Hi,

I've an Europa TC with chassis for 365 gearbox.

The front lower pivot pin is ripped out from its position, so i think is better to rebuilt a front section.

I would like to you know which repair did you do on your car.

Thank you

[europaspecial73]

Hello,

Sorry for the delay. I am currently repairing the original chassis. Front section was cut off and rest of the chassis was blasted and power coated. New front section is being manufactured according to dimensions from the original chassis and dimensions posted on this thread (some slight modifications.) Attached image is distorted on the left side due to preview function of the software. Next step is to assemble the laser-cut pieces together, powder coat the front section and weld it back to the chassis.

[jbcollier]

The front section is actually double box sectioned for greater strength.

[BDA]

My early (pre space frame) Spyder frame makes the front section out of boxes. There is a box that runs between the lower suspension pivots, another between the top pivots, and they are connected with other boxes. Pictures to follow.

I think this is stronger than the original and gives better access to the steering u-joint.

[BDA]

In Front Frame 1, you can see the master cylinder mounted to the lower box. The brake line is attached to the upper box.

In Front Frame 2, you can more clearly see the box layout and if you ignore the anti-roll bar strut, you see there is very good access to the steering u-joint. You can also see the plate that has threaded holes for the steering rack mounts (for either left or right hand drive). You can also see the box that goes from the lower to the upper suspension pivot. It's is "cut-out" and "boxed" in to make room for the shock and spring.

In Front Frame 3, you can see the lower box on the passenger side as well as the mounting plate for the steering rack.

If anyone is interested in more detail so they can fabricate a similar 'T' section, I can try to get more and better pictures.

[gideon]

I have been working on a CAD model for the S2 front box section, which is now very close to the original dimensions and construction.  I started from the drawings posted by Eddie Kirby.  By comparing with the two S2 chassis in my possession I have corrected most of the geometric errors in those drawings. The model is in Autodesk Fusion 360 - which is free for non-commercial use.  I kept Eddie's reworking of the join between backbone and front box at the bottom, which I think was the biggest weakness in the original design.  Otherwise it is faithful to the original.

The S2 box has a folded seam at the front, with a deep flange and two pieces welded in joining the front flange to the back faces.  Eddie got the structure right, it's just a few dimensions that are not quite right.  In one case he was almost exactly one inch out.  The details are clear in his drawings, here:

http://www.lotus-europa.com/manuals/misc/Lotus%20europa%20chassis%20drawing.pdf

I think I'll share the CAD model with the community, now that I'm mostly happy with it.