It's not easy being green - 1971 TC

[Cheguava]

Thanks to all for the input on the door pins. I suspect it'll end up as a hacksaw job, given the way everything else not made of fibreglass seems to have fared...

Worked on with the stripdown this afternoon, another session of mixed progress.    N/s door is now stripped of its door card, internal door locking mechanism, striker and electric winder motor. Drilled out the various rivets, and dug out the mastic round the frame, which is now loose as far as the quarterlight glass, which is not feeling like it wants to move. Am I missing something here? Do I need to winkle out the rubber seal round the glass?  Don't want to break anything, so have left it overnight to read up on.

The electric window winder wouldn't work when I tested it, but you could hear the motor trying both ways. Will separate the motor and mechanism tomorrow and hopefully it's just the mechanism gunged or rusted up, and will free off.

Removed the remains of the seat runner fixings, carpet and underlay/sound deadening, and looked at the seat belt. The buckle mount was not even fixed in, sill mount for the belt will not unfasten so far - I fear the problems that EuropaTC (Brian) had with the strengthening plate may be a problem for me too. Will have a look from the wheelarch, where I will also have to retrieve the door catch that fell into the void!

Finally removed the centre console, which as you can see has had a tough life. plan is to strip it back, fibreglass it up to put the strength back in it, and re-cover it. However, if I delete the ashtray then I can put a screen or phone mount in the space freed up, as a nod to the 21st century. 

Sorry if this sounds a bit whingy - I can't afford a Lotus and a therapist.    Back to it tomorrow.

[Kendo]

There is a very little fastener on the bottom edge of the triangular frame. It might be a rivet. But I used a #2 machine screw and nut when putting it back together. I think its in the front corner. But it's been a while.

[Kendo]

It could be hiding under the rubber surround for the glass.

[Cheguava]

There is a very little fastener on the bottom edge of the triangular frame. It might be a rivet. But I used a #2 machine screw and nut when putting it back together. I think its in the front corner. But it's been a while.

Pretty sure I got that one, had a tiny cross-head screw in it which turned but wouldn't screw out, so dremelled the head off it. Wondering if someone has bonded the quarterlight frame to the door frame. Will have another look tomorrow when my patience is replenished and I don't try and rip it off.

[Kendo]

Yes, that's the one. I dremelled off the heads of the originals, too. For mine, the quarter light frame was gooped with the same mastic as the movable window frame.

[Cheguava]

Yes, that's the one. I dremelled off the heads of the originals, too. For mine, the quarter light frame was gooped with the same mastic as the movable window frame.

That's useful to know, I think that must be what's holding mine in - will try and run a Stanley knife between the quarterlight and door frame tomorrow.

[Cheguava]

Deffo the right decision to sleep and try again in the morning. Managed to ease out the vertical rubber for the quarterlight, and get the glass and then the other two rubbers out. Still couldn't budge the frame, but removal of the quarterlight rubbers revealed a rivet that someone had put through the door frame into the side of the metal channel. Drilled that out and the frame came out.

More progress, the electric window mechanism got cleaned up and moves up and down through its full range, not massively quickly so might still need to check the motor gears and bearing to see if they need fresh grease, but most definitely calling that a win

Finally, the inevitable daft question. There is a crack in the front lip of the "bonnet" surround, as shown in the photo, which needs repairing and probably a bit of lightening subtraction by building the fibreglass up a little behind it. Can I just check that there's nothing missing here - it's just the shape of the fibreglass supporting the panel? 

[Kendo]

That’s the bonnet itself? I had to do that repair also. Yes, it’s just that skirt that stiffens the front edge. Make sure when you reattach the hinge bolts that there is some clearance, or slop in the joints so they don’t pull the bonnet corners out. The parts book calls for a nylon(?) washer between the body and bonnet corners that might help keep the clearance right. A bit of a pain to install.

[Cheguava]

That’s the bonnet itself? I had to do that repair also. Yes, it’s just that skirt that stiffens the front edge. Make sure when you reattach the hinge bolts that there is some clearance, or slop in the joints so they don’t pull the bonnet corners out. The parts book calls for a nylon(?) washer between the body and bonnet corners that might help keep the clearance right. A bit of a pain to install.

Hi, sorry I probably misdirected you - it's the panel in front of the bonnet behind where the badge is mounted. Similar repair I'd guess.

Thanks for the tip on reassembly - already having nightmares about reassembling this after it's had a professional respray - rolls and rolls of low tack masking tape going to be involved I think, plus domestic lifting assistance. 

[Bainford]

 

Sorry if this sounds a bit whingy - I can't afford a Lotus and a therapist. 

That's why we're here.

[EuropaTC]

More progress, the electric window mechanism got cleaned up and moves up and down through its full range, not massively quickly so might still need to check the motor gears and bearing to see if they need fresh grease, but most definitely calling that a win

Ok, I know you're a fair way away from putting the motors back into the doors but when you do, consider fitting relays with a heavy gauge feed to operate the motors. I did that, two small relays (up/down) and it made a phenomenal difference to the speed they operate. Heck, they're like a normal car now !  The bonus is that you're also taking the motor current away from the switches so in theory they should last forever now.

Brian

[Kendo]

I also noticed a minor detail that affected my motors' speed. At the end of the swing arm that raises/lowers the window is a small plastic wheel. The bearing of mine was absolutely caked with dried grease. It took a while to flush out the 50 year old grease. But, re-greased, it now it rolls easily and provides just that little bit less friction in the window mechanism.

[BDA]

EuropaTC’s relay idea is great (and one day I’ll get around to implementing it on my car!) and combining that with a more modern window lift motor might be even better! (https://www.lotuseuropa.org/LotusForum/index.php?topic=971.msg7591#msg7591)

[Cheguava]

Ok, I know you're a fair way away from putting the motors back into the doors but when you do, consider fitting relays with a heavy gauge feed to operate the motors. I did that, two small relays (up/down) and it made a phenomenal difference to the speed they operate. Heck, they're like a normal car now !  The bonus is that you're also taking the motor current away from the switches so in theory they should last forever now.

Brian

That's another very good shout, and pre-empted a question that was already forming in my mind. I was testing the winding mechanism using a 6A battery charger I had, and the current being drawn was in excess of 6A, reinforced by the charger cutting out after half a dozen cycles (oops). So I was wondering just how much current was being drawn, albeit for "only" 10-20 seconds - probably a bit much more than the wiring enjoys. Was already going to add relays to the headlights, looks like another good candidate.

[Cheguava]

I also noticed a minor detail that affected my motors' speed. At the end of the swing arm that raises/lowers the window is a small plastic wheel. The bearing of mine was absolutely caked with dried grease. It took a while to flush out the 50 year old grease. But, re-greased, it now it rolls easily and provides just that little bit less friction in the window mechanism.

Thanks - I'll check that out too. Every little helps!