It's not easy being green - 1971 TC

[Dilkris]

Not that I doubt you - but why would Lotus want to waterproof the bulkhead?

[4129R]

Not that I doubt you - but why would Lotus want to waterproof the bulkhead?

Rainwater getting splashed up into the engine bay would get absorbed by the cardboard material used in the bulkhead.

Many Europas suffer from that cardboard crumbling as it is saturated. You have to remove the defective cardboard and replace with plywood and fibreglass over the plywood. Wet cardboard just falls apart.

[BDA]

I found this thread on the LotusEuropa group that might give you some ideas (https://groups.io/g/LotusEuropa/topic/71913211#msg161028).

[Kendo]

The original bulkhead, at least on my TCS was made from particle board., which is probably as absorbent as cardboard. As I understand it, its main function is to stiffen the body perpendicular to the fore/aft axis.

Since mine was decomposed, I replaced it with 1/2”? The right thickness of marine grade plywood. But others have used honeycomb aluminum and other extremely stiff, and fireproof, panels. Others still have added soundproofing to the cabin side. Ill probably add that when I do the interior in the next few months

[gideon]

The bulkhead serves all three purposes: structural, fire barrier and soundproofing.  The structural part is (I believe) low density fiberboard (LDF).  On the engine side is a layer of sound deadening felt with latex waterproofing, similar to this

https://www.woolies-trim.co.uk/p-1384-sound-deadening-felt

The sound deadening felt from Woolies is also fire retardant.  On the cabin side is a sheet of hardboard (aka beaverboard, masonite, etc.)  covered in carpet (but you all knew that).

[Cheguava]

It's been a little while since I last posted, but I've been soldiering on, and am delighted to announce that the car is back on its wheels. The suspension's very poor though, and it handles like a shopping trolley.    Currently awaiting collection by the bodyshop, but they want to get a current project out of the door before taking mine in, which is absolutely fair but I have no patience. Anyway, have started cracking on loosening bolts all round the chassis so I can get it all apart, and just took delivery of an engine crane to get the engine and transmission out.

As previously stated, looks like a new chassis will be incoming, along with most other metallic bits. I think the wishbones may be ok once blasted or dipped - this one that some numbskull put a jack under looks salvageable but we'll see better once it's off. Pretty much every brake component bar the disc shrouds is going to need replacing I think, and every suspension component too bar the wishbones if they can be saved. Woodman's axe anyone?

Looking on the bright side, the engine number does tie up with the registration, and is the period correct V prefix denoting S/E Dellorto - Domestic Europa very late 1971, and I can expect a heady 112-115bhp according to Miles Wilkins. In two minds about the engine at present, will be getting the top cover off to inspect the top of the head and timing chain etc, and inspect the bores etc using a camera. However, the best time to get the engine overhauled professionally would be when you've stripped the car right down, not after putting it back together!

[berni29]

Hi

There is a 6mm fireproof composite board available the would be great for a replacement firewall. Its commonly used as a tile backer board. Something like this:

https://www.flooringmaterials.co.uk/product/wedi-6mm-tile-backer-board-1250mm-x-600mm

Very light, super stiff, can cut with a box cutter. Would glass in easily.

Berni

[richyb66]

The thread seems to have moved on a bit from discussions on chassis and I've only just picked it up so apologies if this has already been noted.

There is CAD data for the front chassis section on the forum is this thread I created:

https://www.lotuseuropa.org/LotusForum/index.php?topic=6397.0

This might be another option as opposed to a new space frame (and certainly much cheaper).

[Cheguava]

Hi

There is a 6mm fireproof composite board available the would be great for a replacement firewall. Its commonly used as a tile backer board. Something like this:

https://www.flooringmaterials.co.uk/product/wedi-6mm-tile-backer-board-1250mm-x-600mm

Very light, super stiff, can cut with a box cutter. Would glass in easily.

Berni

Thanks Berni, I was thinking of using marine ply but that looks like it would do the job better.

[gideon]

That wedi product is a fibre cement skin over extruded polystyrene core.  It's relatively weak and brittle, and that makes me twitch at the thought of putting it in a car.  According to Mike Kimberley, the firewall is a structural element.  He wanted marine ply and argued with ACBC about it.  We know who won that argument at first, but Mike got his way eventually and the Esprit got a marine ply firewall.

The firewall assembly can be made fire resistant by adding a fireproof layer on the engine side, even if the structural part isn't itself totally fireproof.  For what it's worth, if you were building an experimental aircraft, the FAA would accept a 0.015 inch thick layer of stainless steel as your firewall.  Of course that's overkill for a car, but it makes a point.

Marine ply is one good option for the structural part, but there are also a variety of premade sandwich panels available that would be stronger than this tile backer board, and lighter than marine ply.  If you are comfortable with glassing things in then you could make your own.  I think end grain balsa would be a good choice for a core material.  It has excellent structural properties, it's light, affordable and very easy to work with. 

https://www.eaa.org/eaa/aircraft-building/builderresources/while-youre-building/building-articles/engines-and-firewalls/firewalls
https://www.easycomposites.co.uk/foam-cored-carbon-fibre-panel
https://www.ecfibreglasssupplies.co.uk/end-grain-balsa-wood

[TurboFource]

I am going to try Coosa Board when I get to that point , it’s from the marine industry and is supposed to be flame retardant etc

[gideon]

Yes, it looks like Coosa board could fit the bill.

[Cheguava]

That wedi product is a fibre cement skin over extruded polystyrene core.  It's relatively weak and brittle, and that makes me twitch at the thought of putting it in a car.  According to Mike Kimberley, the firewall is a structural element.  He wanted marine ply and argued with ACBC about it.  We know who won that argument at first, but Mike got his way eventually and the Esprit got a marine ply firewall.

The firewall assembly can be made fire resistant by adding a fireproof layer on the engine side, even if the structural part isn't itself totally fireproof.  For what it's worth, if you were building an experimental aircraft, the FAA would accept a 0.015 inch thick layer of stainless steel as your firewall.  Of course that's overkill for a car, but it makes a point.

Marine ply is one good option for the structural part, but there are also a variety of premade sandwich panels available that would be stronger than this tile backer board, and lighter than marine ply.  If you are comfortable with glassing things in then you could make your own.  I think end grain balsa would be a good choice for a core material.  It has excellent structural properties, it's light, affordable and very easy to work with. 

https://www.eaa.org/eaa/aircraft-building/builderresources/while-youre-building/building-articles/engines-and-firewalls/firewalls
https://www.easycomposites.co.uk/foam-cored-carbon-fibre-panel
https://www.ecfibreglasssupplies.co.uk/end-grain-balsa-wood

Thanks for this, much food for thought! I'm happy to glass in the replacement material, which is just as well, as the integrity of the original material has somewhat diminished.

[Cheguava]

The thread seems to have moved on a bit from discussions on chassis and I've only just picked it up so apologies if this has already been noted.

There is CAD data for the front chassis section on the forum is this thread I created:

https://www.lotuseuropa.org/LotusForum/index.php?topic=6397.0

This might be another option as opposed to a new space frame (and certainly much cheaper).

Thanks for pointing this out, may be very helpful to others. Unfortunately not going to be useful for me, as I don't have the skills, and also the chassis is not great behind the T piece - as you might be able to see from the photo the handbrake pivot has been pulled away from the chassis, and the metal is torn. At the base, similarly there seems less metal than originally present. Hence the replacement chassis plan.