Author Topic: It's not easy being green - 1971 TC  (Read 16913 times)

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Offline Dilkris

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Re: It's not easy being green - 1971 TC
« Reply #195 on: Thursday,July 04, 2024, 12:14:12 PM »
 :I-agree:
Get it raised higher as you say - clear the engine from the shell and then your fun begins.  :FUNNY:

Offline Cheguava

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Re: It's not easy being green - 1971 TC
« Reply #196 on: Friday,July 05, 2024, 09:31:39 AM »
:I-agree:
Get it raised higher as you say - clear the engine from the shell and then your fun begins.  :FUNNY:

Thanks Chris and BDA, shouldn't have to lift it that much thank god - miscalculated a bit with the saw horses which otherwise were a good way of obtaining lift off. Rated at 170kg so easily cover a corner weight of the shell.

Been tidying up stuff that I couldn't get to earlier, such as the diagonal brace strut for which the captive nut on the chassis was no longer captive. And removing the number plate light which I was unaware of until I saw Kelvedon had it back in stock.  Not sure if it will mend - at least there's an alternative if I can't glue/clean/solder it up again.

Also looking at getting the fuel tanks out now the body is high enough. Found the attached thread most informative, particularly given the TC workshop manual doesn't seem to cover it. Will have to see if I can beat Chris's total of 4 sheared bolts out of 8 - have sprayed the nuts with releasing fluid but with little hope and even less expectation. Then we will see if the tanks are savable...  https://www.lotuseuropa.org/LotusForum/index.php?topic=4270.msg45904#msg45904
« Last Edit: Friday,July 05, 2024, 09:33:11 AM by Cheguava »

Offline BDA

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Re: It's not easy being green - 1971 TC
« Reply #197 on: Friday,July 05, 2024, 09:35:52 AM »
I believe those festoon lamps are common so I wouldn't bother repairing it unless you're OCD about originally.

Offline 4129R

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Re: It's not easy being green - 1971 TC
« Reply #198 on: Friday,July 05, 2024, 09:37:11 AM »
You will need the body higher for the left tank as the fuel gauge sender bulge makes it harder to come out on the angle.

If the bolts shear, it is no big deal as they are easy to drill and tap when out.

Offline Cheguava

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« Last Edit: Friday,July 05, 2024, 11:22:08 AM by Cheguava »

Offline Cheguava

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Re: It's not easy being green - 1971 TC
« Reply #200 on: Friday,July 05, 2024, 11:04:53 AM »
You will need the body higher for the left tank as the fuel gauge sender bulge makes it harder to come out on the angle.

If the bolts shear, it is no big deal as they are easy to drill and tap when out.

Thanks - think I've got enough clearance to drop the tanks out but hopefully will soon find out!  ;D

Offline Kendo

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Re: It's not easy being green - 1971 TC
« Reply #201 on: Friday,July 05, 2024, 01:08:57 PM »
Will have to see if I can beat Chris's total of 4 sheared bolts out of 8

My TCS had all 8 bolts. But 3 of the fender washers had punched neat holes through the fiberglass. So I got to patch those and relocate/drill the mounting holes. That was some interesting geometry.

Offline berni29

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Re: It's not easy being green - 1971 TC
« Reply #202 on: Friday,July 05, 2024, 01:30:37 PM »
Hi

You might be lucky. All 8 bolts came out easily on mine. One was actually loose. I thought the tanks would be toast, but the powdercoaters said that after blasting they were ok.

Best of luck

Berni
Also have some +2's

Offline Dilkris

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Re: It's not easy being green - 1971 TC
« Reply #203 on: Saturday,July 06, 2024, 12:51:13 AM »
Fingers crossed your fuel sender fixing arrangement is not rusted solid - mine was, and that your fuel outlet pipes are in good condition - mine weren't.... and that the top of your tanks are not badly rusted c/w pin holes. (mine weren't !! )
There is also an interesting thread somewhere about increasing the fuel pipe size outlets so as to speed up the transfer of fuel from one tank to the other whilst filling up at the fuel station.
If all plans fail - and if you have access to a money tree - aluminum tanks are readily available.   

Offline Cheguava

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Re: It's not easy being green - 1971 TC
« Reply #204 on: Sunday,July 07, 2024, 04:14:27 AM »
So, fuel tanks removed. Only snapped 7 threads - had to grind the head off one bolt as it had rusted so badly that even my socket that grips on the flat couldn't get purchase. Not going to lie, after striking out completely on the RHS, it was clear that penetrating fluids weren't going to assist so I moved straight to shearing the heads off, figuring I could drill them later with better access if the tanks were savable.

Which was probably a fair approach, as the tanks are in poor shape. The LHS one I can see a hole in the bottom by looking in the top, and that's before any wire brush action. I know you can get tank liner, and I was planning on getting some, but unless anyone thinks these are fixable, I think we're looking at replacements. I don't have a magic money tree, but I did budget for this kind of setback, so looks like I'm in for a shiny set of new tanks...

Offline 4129R

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Re: It's not easy being green - 1971 TC
« Reply #205 on: Sunday,July 07, 2024, 04:35:21 AM »
SJS ally tanks are good quality. You will need 8 metric bolts.

Offline Cheguava

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Re: It's not easy being green - 1971 TC
« Reply #206 on: Sunday,July 07, 2024, 08:08:24 AM »
SJS ally tanks are good quality. You will need 8 metric bolts.

Thanks for the recommendation. Will be having a shop around, but they do look pretty nice.

Offline EuropaTC

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Re: It's not easy being green - 1971 TC
« Reply #207 on: Sunday,July 07, 2024, 09:08:06 AM »
To be honest the SJS tanks don't seem that badly priced given what's charged for other Lotus tanks, but if you can weld they're probably the easiest tank to DIY and you'll save a fair bit of the budget for stuff you can't do yourself.   If you can weld and have a MIG set, then read on.

You can weld aluminium with a MIG welder, just use Al wire, Argon gas. Normally people on car forums think "TIG" for Aluminium but you don't need an A/C TIG set. Loads of aluminium is welded commercially with MIG, faster and much cheaper.    As for the tanks, it's literally roll a sheet around a former and weld, slap on the end plates and you're 80% done.  The tank with the sender is more complex but if you've got the first one made then you'll figure the second out, just a bit more welding. 

I made mine in the 80s when there were literally none available anywhere, at any price. Not Lotus, Chris Neils, Spyder, none at all, the best I got was 2-3 months delivery. But it was my daily car so needed fixing PDQ. I can't recall how long it took but it was probably one of those weekend jobs, pull one out on Friday after work, hack a plywood former, weld it up for Sunday afternoon.

Still there, 35+yrs later.....   but I do wish I'd fitted a larger bore crossover pipe, that was a slip-up.

Offline Cheguava

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Re: It's not easy being green - 1971 TC
« Reply #208 on: Sunday,July 07, 2024, 10:20:24 AM »
Thanks Brian - I can weld, but I would class my welding as "effective but ugly", or to steal a phrase I heard that fits it perfectly - "the grinder and paint makes me the welder I ain't"  :))  I have welded up several cars whose integrity after the metal stitching was at least as strong as OEM, or in the case of the mini I seam welded up that would lift a front wheel as well when you jacked it up at the rear jacking point, rather more. But welding is not my lane, and for once, I'm staying out of it. Also, as a wiser man than me said, replace the tanks and get on with the next issue, and I have more than enough issues to address.

BTW I do appreciate the input though - this project is as much intellectual as physical stimulation, and I am very much enjoying the journey to understanding the car I'm rebuilding, even if the learning curve is quite steep at times.  :FUNNY:
« Last Edit: Sunday,July 07, 2024, 10:35:01 AM by Cheguava »

Offline Dilkris

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Re: It's not easy being green - 1971 TC
« Reply #209 on: Sunday,July 07, 2024, 10:33:57 AM »
Sleurs Motorsport - Episode 33 covers the making of aluminum fuel tanks - see link below:-
 
https://www.youtube.com/watch?v=ZDdLgLopw8g

I was highly impressed with this man's skill set which is way above mine. Well worth watching.

In fact I think you'll find that whole series of value - (well, I did anyway)
« Last Edit: Sunday,July 07, 2024, 10:46:27 AM by Dilkris »