Frame inspection

[TurboFource]

When looking at an Europa can you actually see the "T" section of the frame to inspect it while the body is still on ? Maybe with an inspection scope?

[tedtaylor]

since 99.9% of the time any rust is along the bottom, it is clearly visible from underneath.   all the critical suspension points are also clearly visible from underneath and from the wheel wells.   I don't believe "cracks" are an issue at all.    So body on inspections should be sufficient.

[jbcollier]

Not in an S1 but all the others, yes.

On an S1 the front of the T is open to the front compartment.  Reach in with an ice pick and poke HARD at the bottom and corners.  Next lift off the centre armrest and reach in a poke around in there as well.

On S2 and up you need to get the car up on stands or a hoist to get underneath.  Again, get vicious with the ice pick.

Very, very carefully inspect where the front lower a-arms attach to the frame.  Any distortion means the frame has to come out for major repair or replacement.

[TurboFource]

Thanks for advice!

[TurboFource]

Are detailed drawings available for frames? Just thinking ahead........I was an aircraft welder and machinist in the  Air Force and repaired SR-71 and other aircraft parts....I am sure I could repair a Europa frame if need be 

[Chuck Nukem]

Here's a drawing for S2
http://www.lotus-europa.com/manuals/misc/Lotus%20europa%20chassis%20drawing.pdf

[BDA]

The S2 workshop manual has pretty detailed drawings for those frames (http://lotus-europa.com/manuals/s2work/diagrams/index.htm). There are also some drawings here (https://drive.google.com/drive/folders/1szP1L6-cHpjrGMF2dAiyQrY_aR-ZWDJM) but I haven't seen one for the TC. I'm sure that if you worked on SR-71s (Yousa!!) and there is a significant amount of a frame left that you'll be able to recreate (and even improve) a frame. If you do get caught up in that project, try to expand access to things like the steering u-joint, e-brake adjustment, shift linkage and shift lever. I have an early Spyder (before they went to their tube frame. It has much better access to those areas. Richard's (Europa Engineering) frames have a similar treatment for the front 'T' section (https://www.lotus-supplies.com/part-category/chassis/).

SR-71, eh!!!! What an amazing bird to work on! I'm more than impressed!

[TurboFource]

I was stationed at Beale AFB when they retired the SR-71. It was impressive!

[BDA]

I've seen the one at the Air & Space museum at Dulles. Too cool!

[gideon]

There's also a CAD model of the front T piece here

http://www.lotuseuropa.org/LotusForum/index.php?topic=3020

S2 frames commonly crack at the junction between the backbone and the front T, at the bottom.  I don't think there's a way to get sight of it without lifting the body off.  It's a design flaw.

[lotusfanatic]

Hi Gideon,

will you be creating a CAD model of the S1 chassis?

Mark

[TurboFource]

Thanks!

[gideon]

will you be creating a CAD model of the S1 chassis?

No.  I made the CAD model of the T cross piece (front box) for the S2 frame because I planned to remake that part for my project.  But when I saw the S2 frame listed at R.D. Enterprises I decided to take the easy route and buy that. Thanks go to BDA for posting the link.  So now I won't be making that piece, but I will do a little bit of work to strengthen the connection between the backbone and the front box.

You are welcome to take what I have done and adapt or improve it as you see fit.  If you do it would be nice if you also share your work with the community.

[Roger]

since 99.9% of the time any rust is along the bottom, it is clearly visible from underneath.   all the critical suspension points are also clearly visible from underneath and from the wheel wells.   I don't believe "cracks" are an issue at all.    So body on inspections should be sufficient.

When I took the body off my TC there was quite a bit of rust on top of the frame, invisible from underneath. It wasn't enough to have made much penetration, but clearly would have in time.

[Bart]

On my TCS there was rust on the top of the chassis and down the sides at the beginning of the  Y section and going forward towards the gear stick. It was quite pitted but no penetration. This is impossible to see with the bodywork on.