Reducing Vehicle Weight

[literarymadness]

What have you guys done to lighten your Europa? I have done a lot but I am sure there is more I can do. I am open to suggestions. In the rear, I have removed the emissions (cross pipes and evap tank).  Went from a 31 lbs battery to a 4 1/2 lbs one.  Cast iron manifold to a mild steel one and stainless steel muffler (guessing saved 10 lbs). Gear reduction starter (saved 2-3 lbs).  Aluminum flywheel (saved 8 lbs). Removing the brake servos would save 25 lbs but I haven't done it yet. Triple core aluminum radiator ( guessing saved about 18 lbs). I am going to go to a weigh station in the next few weeks to see where I am at. 

[4129R]

Spare wheel, luggage tray, heater, interior fan, carpets, the list is long.

The racing versions apparently had special thin fibreglass shells too.

You could remove both window motors too, and have a manual opening system.

It all depends how extreme you want to go, and why.

Single fuel tank, less fuel in the tank, driver to lose weight, no passenger, etc, etc.

[Steve_Lindford]

If you just want to go a bit faster - there must be easier ways - such as mixing methanol to the fuel??

[literarymadness]

A Federal spec Twink is about 1650 lbs, a hundred more than the domestic or ROW version.  My intention is just to get it closer to or better than the non-Fed version by eliminating what I don't need.  I have kept the spare tire because that is more of safety feature.  Removing the heater seems like good idea because living in South Florida, you don't really need one.  I think I could live without the brake servos if the car's weight was closer to that of an S2.  I am running about 110 hp at the rear wheels so that combined with knocking off a hundred lbs makes my TCS feel significantly improved but still maintaining the spirit of the original car.  I have also tried to dial in my handling as well.  I think 4129r suggestion of reducing driver's weight is the cheapest solution.  I would also be saving quite a few lbs  in addition to a few laughs from spectators watching me get in or out. LOL Maybe even less people would ask the tired question of "How do I fit in that thing?" I was also just curious to see what other forum members have done to their cars and perhaps learn a thing or two.

[Certified Lotus]

Literarymadness, I have done the same as you including getting rid of the servos and all associated piping & valves.

The quest for lighter weight becomes an obsession and goes from removing things to replacing with lighter weight materials that cost a lot of $$$$.

I’ve gone that route with sail boats, road bicycles and track cars. In the end, I have found the best improvement is to enhance your skills. Making things lighter and having the same skills is a zero sum game.

[surfguitar58]

The aftermarket starter and alternator are lighter than stock. Alum vs steel alternator pulley is good for a pound or two. My PO removed the heater core, saving a few pounds but making mine a summer-only car. Emissions and servos are gone. Lighter battery, as you said. I recently added a spare tire and jack, sending me back in the other direction. I still have copper radiator and 2 steel fuel tanks. I would guess my car is about 100 to 150 lbs lighter than stock.
Tom

[BDA]

I have not made an effort to save weight, but I've done some of the things you described, for example, gear reduction starter, aluminum fuel tanks and header tank, no emissions gear, stainless headers and exhaust (though steel muffler), and since my tires are bigger than stock, I don't carry a spare. On the other hand, I've kept brake boosters, I've added front vented brakes (rear discs, too, but I'm not sure they made a difference either way), the early version of Richard's twin link rear suspension is certainly heavier than the stock setup, my engine could be a bit heavier than the TC motor but my oil tank, oil cooler, plumbing is going to be heavier and I have a regular battery.

Shortly after I got my car on the road I had it weighed. It was 1660# with me in it. Figure I weighed about 200# and you get a vehicle weight a little north of 1400#. I guess you have to decide if it's worth it to get closer to 1400# for weight saving's sake.

[gideon]

When I removed the front wishbones+hub+brakes+spring+damper I was surprised at how heavy the whole assembly was.  The stock brake caliper is particularly heavy.  So aluminium hubs, dampers and brake calipers are definitely on the shopping list.

[literarymadness]

BDA is your engine block aluminum? Very impressive weight. Hopefully sometime in the near future I'm going to do the tail of the dragon run like I spoke about before and would love to see your your Europa in person. And so far everybody has given me some great suggestions and food for thought.

[BDA]

Hey 'Madness,

No, I have a cast iron block and it was expensive enough! I shudder to think what my engine in an aluminum block would have cost me!!

I'm thinking I may have overstated the weigh cost of my engine. The BDA had is probably heavier, the carbs are probably a bit heavier too, but then there's no front timing chain box, but the intake manifolds are surely lighter as is the oil pan. It may not be significantly heavier and could even be a little lighter but I would be surprised if there was that much difference either way.

Hopefully we'll be able to meet at a LOG sometime soon! That would be great!

[GavinT]

I’ve seriously thought about making some sort of composite seats (without getting tangled in the intricacies of carbon fibre).
Those seats are heavy.

[4129R]

I’ve seriously thought about making some sort of composite seats (without getting tangled in the intricacies of carbon fibre).
Those seats are heavy.

I had ally frames made. Not cheap.

If you get frames made, get more holes cut in them where it is not crucial, to save weight.

I have new ally tanks, not cheap.

I changed the closer plate under the rack from steel to ally.

To be fair to Colin Chapman there is not much extra weight that can easily be shed. I have many of the components lying around and the main weights are the rear drums, the front discs and calipers, the engine and gearbox. Not much can be shed from those.

In motorsport, holes get drilled everywhere to reduce weight to the homologated minimum or less, then lead added to the minimum and the lowest part in the middle to reduce body roll.

[GavinT]

I had ally frames made. Not cheap.

I don't suppose you weighed the ally ones against the steel ones?

I have many of the components lying around and the main weights are the rear drums, the front discs and calipers, the engine and gearbox. Not much can be shed from those.

True enough though there are ally hubs available . . and that's unsprung weight, also.

[Pfreen]

Mr. madness asked me to weigh my spare, which I have removed from my car.  I put the boosters in the front, so the spare doesn't fit any more.

Anyway, the Lotus alloy rim with a very old Goodyear 165/70-13 tire weighs 29.9 pounds.

[4129R]

I had ally frames made. Not cheap.

Q: I don't suppose you weighed the ally ones against the steel ones?

 A:The ally ones were made because the metal worm had eaten away the bottom 6" of the steel ones !!!

The screen leakss, water gets into the seat area and cannot drain, everything steel up to the water depth rusts away including foot pedals, clutch cable bracket, all cables, seat runners and seats. The seat runners are no longer available, the seat frames are very expensive to re-create, hence very expensive windscreen leak.