new owner '74 TCS misc ?

[BDA]

As Bryan said, there’s no reason to suspect a problem with your stub axles. That’s what the generally look like. JB is also correct about the uprights. Un unfortunately, there is no practical (for most of us garage wrenches) way to measure them before putting them on the car.

They seem to have designed a grease cap that is impossible to take off without destroying it, but you can foil their evil plans. You can screw a sheet metal screw into the hole that bites into the cap. It needs to be long enough so that when the screw reaches the stub axle, it will pull the cap off. I tacked 10-32 nuts in my caps for that purpose.

[Lumbes]

Excellent.  Thank you.

[Bryan Boyle]

Uprights bend easily.  After it is all assembled, get a full wheel alignment and check the KPI.  If it is off, your uprights are bent.  Mine were.

I had made a metal gauge to check uprights off the car...have to look and see if I can find it.  Been almost a decade and a half since I needed it.  Luckily, they parts,  if you need them, are available from not only the usual suspects over this side, but Moss (under the GT6 heading).  (Too bad they didn't use more of the suspension bits, like the arms, from the GT6).

[BDA]

I’d be interested in that gauge, Bryan - either in how to make one or possibly buying one, but certainly to see what it looks like.

[Lumbes]

Rebuilt the hub fully then started assembly.  Nothing is torqued just tightened up enough to keep stuff from sliding around on the threads as I play around.  Two questions, first being the anti roll bar to shock mounts.  How difficult is it to reattach?  I stuck the side with the new shock then went to attach the other side to the original and there is a few inches of space between the two.  Too far to comfortably wrestle it over the shock stud.  Maybe I bent the anti roll bar when fighting the drop links on to it?  Second question, the hub grease cap.  Should I fill that with grease as well?  I packed the hub, not fully leaving room for expansion but was wondering if the hub grease cap should be left empty or filled?

[jbcollier]

The expression is "pack your hubs with grease" but you don't actually do that.  You pack the bearings.  Put a good sized dollop of grease into the palm of your hand and press the side of the bearing into it, forcing the grease into the bearing and out the other side.  Keep rotating the bearing until it is fully "packed".

https://knowhow.napaonline.com/dirty-jobs-pack-wheel-bearing/

Coat the inside of the hub and cap with grease to prevent rust.

Packing more grease than that into the hub does nothing but make a mess.  It will not later flow into the bearings.

[cazman]

From what I know the anti roll bar difficulty is normal. I attach a ratchet strap to one end of the bar to "persuade" it into place. Works well after you get the hang of it.

[BDA]

I have found that there is a suspension position where the roll bar attaches more easily. IIRC, it is closer to ride height. I also found it easier to do both ends at the same time. I might have even put the car on the floor to attach both sides.  Sorry I don’t remember any more details than that. I think if you fiddle with it, you’ll figure it out.

[Lumbes]

Appreciate all the feedback.  Thank you JB for watching out for the Lotus, I did pack the bearings in just the manner you explained.  I then put grease in the hub, roughly the same amount that was in it.  I will coat the cap with sum grease to prevent rust and install the cap tonight.  Will be trying the roll bar to shock mounts tonight too. Thank you cazman for the suggestion I have plenty of ratchet straps that are suitable for the task and BDA I was thinking it looked like it would line up better with the car lowered.  Thinking it will go well enough.  Really, it doesn't need to go on tonight as I plan rebuild the front right suspension and hub in a few days from now.  Just wanted to demonstrate the process to make sure I knew how to do it and that I didn't put something on incorrectly. 

[69merc]

I concur with BDA…..it will line up with the suspension compressed.  I used my floor jacks to compress each side and it will line up. 

[kram350kram]

If in need of a new top wishbone pivot bolt, try Mc MasterCarr. They have grade bolts that will do the job. 

[jbcollier]

The upper a-arm pivot is a pin, not a bolt.  It is threaded at the ends with one end having its nut welded on but there is no load bearing on threaded surfaces.  This is very important.  Do not use threaded rod, no matter its grade!

[kram350kram]

1/2” pin with welded nuts. Long bolt with formed head. Same difference. Get a long bolt ,no major bearing on the threads goes without saying.

[jbcollier]

Yup, I know you know, just want to make sure other people don't wing it.

[Fotog]

Are you aware about the issue of "too thick felt grease seals" on the inside of the front axle?  Just FYI-ing you.
Some discussion here: http://www.lotuseuropa.org/LotusForum/index.php?topic=5375.msg57856#msg57856