Revival of Lotus Elise S1 (1998)

Revival of Lotus Elise S1 (1998)

Author
Discussion

Smokin Donut

Original Poster:

273 posts

225 months

Thursday 3rd May 2018
quotequote all
Krikkit said:
What a cracking read, congrats! Lots of really nice touches gone into this, bits that only you'll notice, but that's one of the most satisfying parts.

Obviously it's no help now, but with the pressure bleeder (Eezibleed), I find that the standard cap set can be a bit limited, and unless it's identical it always leaks.

The easiest way is to buy another cap for the reservoir and drill the small diameter hole in the top the bleeder requires for the fitting. I'm building up a nice little collection now. smile
LOL now you tell me! I ended up using miles of thread tape to get the cap to seal.

NNH

1,515 posts

131 months

Thursday 3rd May 2018
quotequote all
Beautiful car, and amazing work from you. I can't wait to see the next steps.

Smokin Donut

Original Poster:

273 posts

225 months

Friday 4th May 2018
quotequote all
NNH said:
Beautiful car, and amazing work from you. I can't wait to see the next steps.
Thanks, next steps are to upgrade the shocks, refresh the wheels and get some sticky tyres.

olly22n said:
Fantastic work!

Good to hear you’re doing a home geo - having done this myself buy the thickest fishing line, a digital vernier calliper and a whiteboard!

Looking forward to the results
Thanks for the tips, I have a plan and no idea if it'll work! But the parts are 25% of the cost of a professional geo, so nothing to loose. I'm lucky enough to have a flat level garage floor which helps. Anyone know what you can put under the tyres to allow them to settle, instead of having to roll the car in and out of the garage after each adjustment? Perhaps a thin plastic chopping board on grease?

Smitters

3,995 posts

156 months

Friday 4th May 2018
quotequote all
Inspired me to get out and do a few of the niggle little jobs I've been meaning to get round to. I used many, many magic sponges on the interior and then a liberal spray of anti-corrosion stuff and it all looks really nice now.

Just got some cables to free up (like the heater/air direction one, as per yours) and I'm ready for summer.

Integra99

24 posts

70 months

Friday 4th May 2018
quotequote all

Nice thread, envious of you coming into pocession.. I've had lots of Lotus Elises.. nice little thread and such and in my opinion a lovely car to work on and quite cheap to tidy up! Assume Elise Parts still exits!

My 22mm socket in my beloved took box is still cut down in order to do the crank.. ha ha . always bring fond memories when using it.. along with a hug bar I mad to wind in the renault rear calipers!


Smokin Donut

Original Poster:

273 posts

225 months

Friday 4th May 2018
quotequote all
Integra99 said:
Nice thread, envious of you coming into pocession.. I've had lots of Lotus Elises.. nice little thread and such and in my opinion a lovely car to work on and quite cheap to tidy up! Assume Elise Parts still exits!

My 22mm socket in my beloved took box is still cut down in order to do the crank.. ha ha . always bring fond memories when using it.. along with a hug bar I mad to wind in the renault rear calipers!
That last bit made me smile, I also haven't got round to replacing my cut down 22mm socket! These little cars do grow on you, I'm always surprised how many are still with their original owners.

lockhart flawse

2,040 posts

234 months

Friday 4th May 2018
quotequote all
Great job OP and just in time for summer......

I would like to try a Lotus at some point but not at the expense of my Griffith....

Smokin Donut

Original Poster:

273 posts

225 months

Saturday 5th May 2018
quotequote all
Nice setup. Pretty much what I have in mind. Except with an inclinometer for the caster. The tiles are a great idea.

MB140

4,027 posts

102 months

Sunday 6th May 2018
quotequote all
Smokin Donut said:
Thanks for the tips, I have a plan and no idea if it'll work! But the parts are 25% of the cost of a professional geo, so nothing to loose. I'm lucky enough to have a flat level garage floor which helps. Anyone know what you can put under the tyres to allow them to settle, instead of having to roll the car in and out of the garage after each adjustment? Perhaps a thin plastic chopping board on grease?
Trays from McDonald’s. With appropriate lubrication on the bottom.

Smokin Donut

Original Poster:

273 posts

225 months

Wednesday 23rd May 2018
quotequote all
After a couple of short drives it was clear there was something not right with the rear of the car. I suspected it was the tracking but I had carefully matched the lengths of the old and new toe links. So back in the garage for a check of the geo.

The poles at each end were to create an exactly parallel box. I setup the box so that:
- The distance between the fishing lines on the 2 poles were the same.
- The line ran through the center of the wheels (hence cardboard packers).
- The distance from the line to the center of each wheel on each axle was exactly the same.
- The distance of the pole from the rear tyres were the same left to right.
I’m sure there is an easier way of doing this but it worked for me.






Then I measured from the line to the front and back of the rear wheels and the difference gave me the toe measurement. Larger forward number = toe in.



I was aiming for the 340R road settings which are 1.5mm toe in each side. I had 15mm of toe in each side!! yikes No wonder the rear had been feeling squirrely. I have no idea how I got them both that far out? confused




I could reach the toe link locking nuts and adjustment bar with the car on the ground so proceeded to shorten the bars till I had 1.5mm of toe in. Then rolled the car backwards and forwards to let the tyres settle before giving it a final check. I will have to get some plastic trays to place under the wheels in future! Plus buy a digital vernier clipper as manually reading the vernier scale over and over again was driving me nuts!

To adjust the front wheels I had to jack up the car to reach the front steering arms. These are turned using a pair of mole grips, which trashed the new paint. The front wheels were set to 0.2mm toe out with the steering wheel straight. Then I removed the jack, rolled the car backwards and forwards and checked again. It was 0.5mm toe out which will be fine

I needed to use the car so just had a quick check of the camber using a digital angle gauge calibrated using a spirit level. The figures were close enough and I’ll have a go at getting them perfect later.

Then I took the car for a drive………….what a difference, the handling was back to how Lotus intended. So off to enjoy the sunshine! biggrin



I have plans for the Elise and will keep improving her, but for now my wife and I are enjoying driving her too much to take her off the road. And the new shower cap has proved a great hit!

anonymous-user

53 months

Wednesday 23rd May 2018
quotequote all
What a great read! I was running past the entrance to Brands today and a load of track prepped Loti were arriving, Exiges of all kinds, motorsport Elise, lots of wings and flaps and angular intakes. And one S1 Elise, which just looked really pure and simple in comparison. I'd be happy with any of those cars, but what a great design the original Elise was.

Smokin Donut

Original Poster:

273 posts

225 months

Wednesday 6th June 2018
quotequote all
I was feeling a slight vibration at about 80mph so decided to get all the wheels balanced. All were good except for the front left which was buckled. I don’t think it’s fixable as the whole wheel is out of round. I’m not sure how you achieve that on a car that weighs 700kg? So the hunt was on for a new front wheel. Problem is they are no longer made and most of the second hand ones have issues. Luckily I found a guy on SELOC who was selling a low mileage wheel. It had apparently been stored for years, was in mint condition and still had the original paint. A few emails later and after handing over £120 a box arrived that made me a very happy boy! The wheel is mint and obviously not done many miles.




To accompany the new wheel I’m going to fit a set of Yohohama Advan Neova AD08R’s which seem to be the go to performance tyre for the Elise. The current tyres have plenty of tread, worked well on track and show no signs of hardening or cracking, but are VERY old!



I’m also in the process of purchasing a new set of seats. The originals were killing my lower back, despite the inflatable lumber support the only way to ‘suffer’ any drive longer than an hour was to put a piece of foam behind my lower back. So after much research and overthinking I’ve chosen a set of Corbeau Le Pro which are designed for the Lotus Elise and fit straight in. Fingers crossed they will be more comfortable.




It’s Elise’s 20th Birthday on the 25th June, so thought it only fair to buy her something nice.

Smokin Donut

Original Poster:

273 posts

225 months

Wednesday 13th June 2018
quotequote all
Today was a good day.
I noticed a written off Elise in an eBay listing (for the engine) and called the breakers to see if the clear rear indicators had been sold. Unfortunately they were already on their way to Japan! However I noticed it had a stainless exhaust so after the exchange of some pictures and £265 I have this lot winging its way to me.



It’s a Brooke Kensington stainless exhaust (which is the one I was planning on buying). Plus an Elise Parts stainless flexible downpipe, cat bypass pipe and OE manifold which was thrown in for free. After I’ve finished polishing up the exhaust it will look as good as new.

Along with half the S1 Elise owners in the world I’ve been on the hunt for a pair of clear front indicators. A few years ago they were readily available but the supply has dried up and they have subsequently become rocking horse poo. Apparently any remaining new sets are swopping hands for up to £300!!



I found a single one on eBay for £64 and against my better judgement quickly pressed ‘buy it now’ wondering what I was going to do with one indicator! Then, under ‘similar items’ I saw the other one. I am now the proud owner of a pair of clear front indicators for a (relative) bargain £128………………………………… I must remember to buy a lottery ticket tonight.

Then my lovely wife went for a drive and took some pics.





Externally she is exactly as she left the factory (apart from the stone chips), which is soon going to change. But I’ll keep all the original bits, so she can be returned to stock. I’m only planning a few subtle changes, nothing radical that will spoil the character of these awesome little cars.

Edited by Smokin Donut on Wednesday 13th June 19:18

Smokin Donut

Original Poster:

273 posts

225 months

Sunday 12th August 2018
quotequote all
The standard exhaust note had always left me a little flat. sounding like a rover 200! So I was on a mission to get the Christopher Neil exhaust fitted ASAP.

I got the car up on the ramps and removed the under trays.



I had no idea how to get the exhaust out but was pretty sure it could be done with the clam on.



The hanger bolts were rusty but came off without too much of fight.



There are 3 hangers, 2 of which are secured to the boot floor.



The cat nuts were much more trouble, with one requiring surgery from the angry grinder.



After a moderate fight the cat was free (- one stud).




Now came the fun part, maneuvering the huge silencer around the lower edge of the clam. With the wife holding the tail pipes and me pulling, pushing and swearing it was finally free.



A little smaller and lighter.



With the old one out it was time to prep the replacement for fitting. I do like a pair of shiny pipes, so out came the polisher.
Before



Pollishing



Mmmm shiny



The hanger rubbers were replaced and the securing plates wire brushed and painted.





Needless to say upon refitting all nuts and bolts were replaced with stainless.



I bought an exhaust change kit which included these very long stainless nuts, after some head scratching I worked out they were for the cat to prevent the studs rusting. As the decat pipe had holes instead of studs I could use standard stainless nuts and bolts. I’m thinking of cutting and drilling out the studs on the cat to make removal and fitting easier.



The new Christopher Neil exhaust went in without issue, is much smaller than the old one and better designed.

I wanted to fit the stainless downpipe as the original ones pretty rusty. When I tried to undo the bolts from down-pipe to manifold the access was rubbish and and I was about to snap a stud which would mean the exhaust manifold would have to come off (which is a mare of a job). I decided the old pipe wasn’t blowing and would last till winter - so gave up!

Sorry for the crap pics!




After a few weeks use, I couldn’t be happier. The sound is amazing at WO throttle, with pops and burbles on the overrun. But when driven sedately (wife) it’s not intrusive at all. I was worried about it booming/droning on the motorway, but I can’t hear it over the wind noise so all’s good! Finally the Elise sounds as good as she looks.



I also fitted the newly painted rear mesh guards that cover the fog light and reversing light.



Time to enjoy the summer and make some noise!

Edited by Smokin Donut on Sunday 12th August 10:21

Krikkit

26,500 posts

180 months

Sunday 12th August 2018
quotequote all
That looks absolutely fantastic, love it!

Can't believe how expensive those indicators were, I actually prefer the ginger ones anyway. biggrin

Smokin Donut

Original Poster:

273 posts

225 months

Sunday 12th August 2018
quotequote all
Krikkit said:
That looks absolutely fantastic, love it!

Can't believe how expensive those indicators were, I actually prefer the ginger ones anyway. biggrin
Thanks.

I have a box of bits waiting to be fitted, but we’re having to much fun driving her so any further mods will have to wait till winter.

Tickle

4,879 posts

203 months

Sunday 12th August 2018
quotequote all
I did a similar thing with a Janspeed Supersport on mine, shot blast and buffed the tips. Very satifying job.

Them lenses are mad prices, if I fall on hard times I may sell mine!

Cars looking good, seats in yet?

Smokin Donut

Original Poster:

273 posts

225 months

Sunday 12th August 2018
quotequote all
Tickle said:
I did a similar thing with a Janspeed Supersport on mine, shot blast and buffed the tips. Very satifying job.

Them lenses are mad prices, if I fall on hard times I may sell mine!

Cars looking good, seats in yet?
Saw an Elise with front and rear clear lights and told the guy they'll soon be worth more than his car! biglaugh

Seats still in the spare room. frown Reason for this is when I get the seats out I plan to wire brush and paint the foot-well floors with POR15. Plus I have a harness bar to fit, new speakers etc. so its not a quick job and has been added to the winter list. Along with the complete rear end refresh. And perhaps a set of 135 cams?

Tickle

4,879 posts

203 months

Sunday 12th August 2018
quotequote all
Smokin Donut said:
Saw an Elise with front and rear clear lights and told the guy they'll soon be worth more than his car! biglaugh

Seats still in the spare room. frown Reason for this is when I get the seats out I plan to wire brush and paint the foot-well floors with POR15. Plus I have a harness bar to fit, new speakers etc. so its not a quick job and has been added to the winter list. Along with the complete rear end refresh. And perhaps a set of 135 cams?
I could sell my lights and get a Honda conversion scratchchinlaugh

I POR'd under my seats when I had them retrimmed. Makes a difference.



Looks like a busy winter for you!

Smokin Donut

Original Poster:

273 posts

225 months

Sunday 12th August 2018
quotequote all
Tickle said:
I could sell my lights and get a Honda conversion scratchchinlaugh

I POR'd under my seats when I had them retrimmed. Makes a difference.



Looks like a busy winter for you!
Nice! If my interior ends up looking half as good as yours I'll be happy. May I ask where you got your carpets from?