making progress

[Bart]

Hi all,

Thought I'd post a quick update on the progress over the holidays of my rebuild. The engine and transmission are now in place and look great.

A few things of note were:-

I did a dry fit of the new exhaust headers and discovered that the temperature control for the heater is in the way   its about 1/8" too proud of the engine and of course I have the concern of how to route the silicone hose to it and avoid touching the header so now I am thinking about what to do about that, I may remote mount the temperature control and run hoses to it not sure yet.

I got the rear suspension dry fit and then disassembled and have now completed the driver side, I forget who posted the method to shim the inboard drive shaft to the output shaft, but it was so simple to do using a thin piece of wire to feel when the holes aligned perfectly and then add one .005 shim to give a tight fit. I did discover that the passenger side out board drive shaft had badly mauled threads and knowing this thing had to be torqued up to 150 I decided to replace it, just waiting on the part to arrive from Ray it's a pain to take the whole assembly apart (again), but my own fault for not paying attention to the condition of the threads!

I learnt a useful lesson too, don't put the engine in before running the emergency brake cables through the tunnel, they have a press fit into the end plate of the tunnel from the engine side and its a bear to get to with the engine in, took over an hour of cussing and laying on my garage floor before I could get them seated, I also learned its really helpful to have a 9 year old with small hands to help sort things out inside the tunnel

Last thing I also discovered that the top thread (in the bell housing) of the center pivot assembly for the gear linkage is stripped, so I have to either take the transmission out, drill it, put in a helicoil and re assemble or leave the transmission in place and drill all the way through the bell housing and then grind a spot to seat a lock nut and use a nut and bolt arrangement not the original bold into a thread. I was told that a nut and bolt arrangement is a stronger way to do it and it makes sense to me that it would be but I am on the fence right now.

Anyhow, as usual it's 2 forward one back but its beginning to look more car like and less a pile of random parts.

Happy New Year to all.

Bart.

[BDA]

Things are starting to come together! Looking good! Any progress is progress!

[jbcollier]

For the heater valve, fit a brass elbow with a long outlet to keep the hose away from the exhaust.  Then fit an inline heater valve.

[Certified Lotus]

I would take the transaxle out now to retread the stripped part. Yes the handbrake mechanism is a pain to install. Be patient. Very nice headers!

[dakazman]

  Wow Bart, engine and frame look great!  I would go with certified and pull the transaxle out and install the helicoil insert. It’s also nice to hear your teaching a 9 year old the basics. I also understand the joy of finding new work space in your garage and shelves.
Dakazman
 

[Bart]

Thanks for the advice all.

The elbow for the heater valve is a great idea thanks for that. I am now resigned to taking the tranny out to put in the helicoil, I know its not that difficult or a lot of time so I think that is the way forward, but man, Helicoils are expensive! I am in the wrong business.

Next item on the list is the gear change linkage rebuild, I have all the parts ready so its hopefully it will be smooth sailing.

More soon,

[BDA]

I would suggest that while the tranny is out that you put helicoils in all the mounting threaded holes. You can get sets for metric and SAE at ebay and Amazon. Buying one kit for one threaded hole is expensive but using them more places makes them more cost effective.

[dakazman]

 Bart , BDA is correct. I purchased a metric set from China. It was perfect-and had a nice selection on all sizes.
131pc Stripped Thread/Rethread Helicoil Repair Kit M5 M6 M8 M10 M12 Metric .
Dakazman

[Bart]

Hi all,

Just to say based on all the input, I did in fact pull the gearbox off again and drilled, tapped and inserted heli coils on all the threads in the bell housing, very satisfied that I now have a better than original way to secure one to the other.

I went out a got an elbow for the heater valve (as suggested) and that worked perfectly to get the valve out of the way of the exhaust.

And finally, in my appeal for the dimensions of the cam pulley that drives the alternator one very kind member of this forum did way better than that, he had a spare one  and sent it to me without charge, now that's  real camaraderie. Thank you!

[Fotog]

Sounds like all good news.  Just watching your progress.... I wonder: where are you in MD as I've gone to Annapolis 100+ times from PA; and where did you get those handsome headers?

Vince

[BDA]

Keep up the good work, Bart! You'll be making noise and then driving in no time! 

[Bart]

Thanks for the encouragement everyone.

Personally I love the look of the headers, I will loose the luggage tray but there is something about them that is so appealing, and I don't plan on luggage.  The headers came from Banks in the UK and were quite an investment. I still have the original header and if its ever a big issue (for resale etc.) I'll swap them out, but as I plan this car will pull the carriage with my box on it, it's not an issue.

I talked to Jet coatings to have them (the headers) ceramic coated and they want $500 to $600 to do it, so I am looking into options on that, I see you can buy home applied ceramic paint for $10 a tin but it needs 650' to cure, where in my house can I get 650' ? A big green egg might get that for a while but not sure where else, I need to find out if I can cure at a lower temp (maybe for longer) and get the same outcome.

I read Bobs book "Europa Euphoria" today, it was amusing and I found myself grinning and sympathizing, getting the doors off has a  particular resonance.

Best to all,

Bart

[surfguitar58]

 I will loose the luggage tray but there is something about them that is so appealing, and I don't plan on luggage. 
Best to all,

Bart

Hi Bart;
I have (and love) a similar header to yours. Regarding the boot tray, Here’s my solution to having my cake and eating it too (while possibly baking it in the trunk to boot!) http://www.lotuseuropa.org/LotusForum/index.php?topic=2433.msg23467#msg23467

[lotusfanatic]

Hi Bart,

that really is some progress!
(even when taking into account the 2 forward/1 back factor)

Mark

[Certified Lotus]

Bart, if it were me I would spend the money to have the headers Jet Hot ceramic coated. It lasts forever, keeps the temp down substantially and looks great. I know easy for me to say and spend your money..........

Think of it this way, every time you open the rear deck to show someone your engine the first thing they will see are those headers.