Lotus 7 S4 1974: light restoration and modification
Discussion
No point in checking in daily. This is a project which is supposed to be finished at easter.
Some things are happening,though but not that much. I have just finished installing the wires permanently. Have relocated the ECU and relay board to inside the footwell, and some other small things.
Car is cranking, all sensors give right values and spark is now good. Only issue is no fuel pressure. Why? Well, in a quest to save time I bought an adjustable fuel pressure regulator off ebay. Installed and ready to go, the Adj FPR gave 8 bar!! before one of the connections gave. It seems the spring inside the regulater is just way off. Dont by critical parts from China!
If I should give a review of the project so far:
1. Duratec is expensive
All parts are more expensive an harder to come by, than equivalent Zetec parts.
2. Duratec is tall
The Duratec is taller than I expected, and a lot of fiddling to get it to work
3. Microsquirt was wrong choice
I chose the Microsquirt ECU since it has all the options I needed and is small and weatherproof. The V3 was supposed to be able to fire wasted spark but after not getting a spark I read the specifications again. It can only fire certain coilpacks, not Ford and 90% of the normal packs. I than had to get hold of an EDIS which I didnt want to in the beginning. This meant I had to rewire the ECU triggering, firing etc.
4. Raceline might not be the best vendor
I have quite a few parts I want to by, such as LSD, proper exaust, water rail +++. Its about 2k in parts.
The only vendor which have all of the products I want is Raceline. After sending them 4 mails, Calling them and explaining, I still get no offer from them. Now it has been 4 weeks and I have to move on...
My issue is that I after this experience I dont want to by from them, but they are the only vendor...
5. Gearbox is bigger issue than Engine
The biggest issue is the 5 speed gearbox. I have solved it without cuting the chassis, but it might cut it in the future depending on how it works out.
So for I would say that this engine swap is quite straight forward, but it might be more cost efficient to go Zetec. I dont know the performance difference between the two, but on paper it doesnt look to different.
I will put in an order for all my parts this week with a vendor, so there should be some updates in 2-3 weeks
Some things are happening,though but not that much. I have just finished installing the wires permanently. Have relocated the ECU and relay board to inside the footwell, and some other small things.
Car is cranking, all sensors give right values and spark is now good. Only issue is no fuel pressure. Why? Well, in a quest to save time I bought an adjustable fuel pressure regulator off ebay. Installed and ready to go, the Adj FPR gave 8 bar!! before one of the connections gave. It seems the spring inside the regulater is just way off. Dont by critical parts from China!
If I should give a review of the project so far:
1. Duratec is expensive
All parts are more expensive an harder to come by, than equivalent Zetec parts.
2. Duratec is tall
The Duratec is taller than I expected, and a lot of fiddling to get it to work
3. Microsquirt was wrong choice
I chose the Microsquirt ECU since it has all the options I needed and is small and weatherproof. The V3 was supposed to be able to fire wasted spark but after not getting a spark I read the specifications again. It can only fire certain coilpacks, not Ford and 90% of the normal packs. I than had to get hold of an EDIS which I didnt want to in the beginning. This meant I had to rewire the ECU triggering, firing etc.
4. Raceline might not be the best vendor
I have quite a few parts I want to by, such as LSD, proper exaust, water rail +++. Its about 2k in parts.
The only vendor which have all of the products I want is Raceline. After sending them 4 mails, Calling them and explaining, I still get no offer from them. Now it has been 4 weeks and I have to move on...
My issue is that I after this experience I dont want to by from them, but they are the only vendor...
5. Gearbox is bigger issue than Engine
The biggest issue is the 5 speed gearbox. I have solved it without cuting the chassis, but it might cut it in the future depending on how it works out.
So for I would say that this engine swap is quite straight forward, but it might be more cost efficient to go Zetec. I dont know the performance difference between the two, but on paper it doesnt look to different.
I will put in an order for all my parts this week with a vendor, so there should be some updates in 2-3 weeks
Hi Knut, - many thanks for the very detailed update. I did not expect that you meet so many different difficulties. Megasquirt has a good reputation normally. I also ran the Edis module in conjunction with the little sister Megajolt (ignition only). For me it looks fine to use and trust this standard, million wise build EDIS plus coilpack - should be working inthe next "50 years". Yout mention LSD. For some years now, I use the Quaife ATB LSD with very good overall performance. This LSD is maintenance free and uses normal diff oil. At a later stage I exchanged the iron diff housing with same looking Aluminium item. This saves nearly 5 kgs. I hope that there will be no further mountains for you and that your 7 is ready for a easter run - Cheers, Hajo
An excellent thread! A really great read. Sure, I am biased about xflows and clamshell wings (especially on the S4) BUT this is YOUR car and you build it the way YOU want. That is what our hobby is all about. Impressed by all your hands-on skills too. It will certainly be a unique car when complete and a considerable track weapon too.
Dave
PS Those S4 clams are like gold dust and worth a small fortune so keep them somewhere safe
PPS Love the 944 too
Dave
PS Those S4 clams are like gold dust and worth a small fortune so keep them somewhere safe
PPS Love the 944 too
wile7, the clams are not really a problem - especially when you know someone with the original lotus factory moulds...(what I luckily do) - Yes, every 7 owner has his individual car - and that´s what makes our hobby so fantastic. And BTW. Dave: Clean looking 7 on your profile!
Edited by 7s4whatelse on Thursday 20th February 15:07
Edited by 7s4whatelse on Friday 21st February 05:38
Thanks guys for following this project and contributing with useful tips. I promise that you all will be surprised by the final look of the car
To clarify on the Microsquirt: I think it is the wrong chosise, since I wanted to have the ignition inside the box. Whith the Microsquirt I have it on the outside. If I should do this again I would have gone Megasquirt II, V3. That has the capability to run the coils directly. I didn't want the EDIS since I want to play with ignition settings, but then again it is a proven concept.
About the Xflow: Yes! fantastic sound! Just lacks the punch. I actually plan to map the Duratec to get fuel overflow on decel just to get the puffs and bangs
Clams are stored if I want to go back. One interesting thing: Clams gives better turning circle, since the stays for the cycle wings interfere with the body at full lock.
Progress:
The vendor Raceline never got back to me eventhoug I spoke with them on the phone and sent them 5-6 mails. Really annoying people! Even more annoying is that one of the parts I bought from Burton Engineering is a Raceline part!
It means that I will have to wait with some bits such as proper exhaust, cams and LSD for next year. But I need to get the car running for easter.
To clarify on the Microsquirt: I think it is the wrong chosise, since I wanted to have the ignition inside the box. Whith the Microsquirt I have it on the outside. If I should do this again I would have gone Megasquirt II, V3. That has the capability to run the coils directly. I didn't want the EDIS since I want to play with ignition settings, but then again it is a proven concept.
About the Xflow: Yes! fantastic sound! Just lacks the punch. I actually plan to map the Duratec to get fuel overflow on decel just to get the puffs and bangs
Clams are stored if I want to go back. One interesting thing: Clams gives better turning circle, since the stays for the cycle wings interfere with the body at full lock.
Progress:
The vendor Raceline never got back to me eventhoug I spoke with them on the phone and sent them 5-6 mails. Really annoying people! Even more annoying is that one of the parts I bought from Burton Engineering is a Raceline part!
It means that I will have to wait with some bits such as proper exhaust, cams and LSD for next year. But I need to get the car running for easter.
I have been following this thread almost since the beginning but this is the first time I have posted here. A bit about myself I live just outside Toronto Canada.....yes...I am a bit of a Lotus nut, have been for a long time. Two years ago I purchased an S4 that was partially race prepped...so last winter I completed it and ran it in various Vintage events in Canada and the US. it is spring now...and time to get the beast back in shape for the coming race season but have a few tasks ahead. One being a Limited Slip Diff, and the other being spare clam shell fenders....just in case. As far as the LSD goes, I will likely be going with a Quaife ATB but haven't taken my existing axles out to see the number of splines...so I have to do that before ordering it. As far as the fenders, I have not come across anyone who has replacement fends, so I think I may end up making molds so that if I need spares I can make them. Same goes for the bonnet....if there are none about, best to make a mold. Any thoughts about spare?
Ugly, please post som pics of your race car
As far as sparese, I think Hajo knows where there are some molds for the fenders..
Here is a nice vid I found with an S4.
http://www.youtube.com/watch?v=2RYAnWNX8mw
As far as sparese, I think Hajo knows where there are some molds for the fenders..
Here is a nice vid I found with an S4.
http://www.youtube.com/watch?v=2RYAnWNX8mw
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