One for the techies... :)
Discussion
Right, been getting to grips with my project car.
First up, got it started: stuck starter solenoid and fuel pump. Now it fires up with a bit of choke, once warm idles about 800rpm. Fans not working so I daren't leave it cooking too long
I get about 55 psi oil pressure cold, dropping to 30-ish (at a guess) when warmed up. Been for a spin, the clutch and 'box work. brakes work but discs rusty.
I've sorted most of the electrical gremlins that were present: the horns and fans are knackered so they'll need fixing properly
Left-hand indicators refuse to work, although they do on Hazard and the rights are OK. All other lights OK now.
Exhaust (full stainless, no centre box, 4-branch manifold) is blowing slightly from a joint somewhere.
Driver's seat frame is missing, seat is not even bolted to floor, I just found out...! I'll probably pinch the passenger one and weld up a fixed frame for that, unless anyone has a spare frame handy?
Mirrors click loudly but don't move.
Header rail (with the mirror on) is loose: that'll need a screw then
O/S handbrake not working. Cable is OK, looks like the caliper (Girling) is stuck. Ten-minute job there...
Some of the brake lines (mostly the inaccessible ones!) are cruddy. Another 10-minute job...
Clutch slave cylnder leaking fluid.
Plan of action, as it needs an MOT; I need to drive it so I can work out what might be seriously wrong:-
1. Overhaul rear calipers. Is there a service kit?
2. Strip front suspension (dampers look iffy). Blast and powder-coat all parts. Renew all bushes. Overhaul steering rack.
3. Replace brake lines as appropriate.
4. Fix blowing exhaust.
5. Fix indicators, horns, fans.
6. Clutch slave cylinder: replace seals or fit new cylinder? If so, cheap supplier of same (in the UK)?.
Any thought on the above, and also:
Can't find the Esprit on Polybush or Superflex listings. Are the standard bushes about right, and if so, where from? No silly prices, needless to say...
The outboard seatbelt mountings must be on a frame within the sill; I presume lifting the carpet reveals an acces panel (since the handbrake is in there too): does this hidden metalwork tend to corrode, and if so is it a bitch to fix? I'm used to TVR wedges, they are easy to get at...
I'm intrigued by the vacuum-operated flap on the air intake up front: the vac capsule works and the flap moves, but I can't feel any suction in the tube no matter what revs I try. Purpose of this assembly?
...and I'm sure there will be plenty more...
Ian
First up, got it started: stuck starter solenoid and fuel pump. Now it fires up with a bit of choke, once warm idles about 800rpm. Fans not working so I daren't leave it cooking too long
I get about 55 psi oil pressure cold, dropping to 30-ish (at a guess) when warmed up. Been for a spin, the clutch and 'box work. brakes work but discs rusty.
I've sorted most of the electrical gremlins that were present: the horns and fans are knackered so they'll need fixing properly
Left-hand indicators refuse to work, although they do on Hazard and the rights are OK. All other lights OK now.
Exhaust (full stainless, no centre box, 4-branch manifold) is blowing slightly from a joint somewhere.
Driver's seat frame is missing, seat is not even bolted to floor, I just found out...! I'll probably pinch the passenger one and weld up a fixed frame for that, unless anyone has a spare frame handy?
Mirrors click loudly but don't move.
Header rail (with the mirror on) is loose: that'll need a screw then
O/S handbrake not working. Cable is OK, looks like the caliper (Girling) is stuck. Ten-minute job there...
Some of the brake lines (mostly the inaccessible ones!) are cruddy. Another 10-minute job...
Clutch slave cylnder leaking fluid.
Plan of action, as it needs an MOT; I need to drive it so I can work out what might be seriously wrong:-
1. Overhaul rear calipers. Is there a service kit?
2. Strip front suspension (dampers look iffy). Blast and powder-coat all parts. Renew all bushes. Overhaul steering rack.
3. Replace brake lines as appropriate.
4. Fix blowing exhaust.
5. Fix indicators, horns, fans.
6. Clutch slave cylinder: replace seals or fit new cylinder? If so, cheap supplier of same (in the UK)?.
Any thought on the above, and also:
Can't find the Esprit on Polybush or Superflex listings. Are the standard bushes about right, and if so, where from? No silly prices, needless to say...
The outboard seatbelt mountings must be on a frame within the sill; I presume lifting the carpet reveals an acces panel (since the handbrake is in there too): does this hidden metalwork tend to corrode, and if so is it a bitch to fix? I'm used to TVR wedges, they are easy to get at...
I'm intrigued by the vacuum-operated flap on the air intake up front: the vac capsule works and the flap moves, but I can't feel any suction in the tube no matter what revs I try. Purpose of this assembly?
...and I'm sure there will be plenty more...
Ian
I have to say: sounds like fun!
There's a pretty tired '86 Turbo around here that has lived outside for several years and is not running. Several of us are planning to get together to at least help the owner get it mobile again but don't think I haven't thought what a fun project it would make!
Too...many...projects...must...RESIST
There's a pretty tired '86 Turbo around here that has lived outside for several years and is not running. Several of us are planning to get together to at least help the owner get it mobile again but don't think I haven't thought what a fun project it would make!
Too...many...projects...must...RESIST
Parts for your car try
www.sjsportscars.co.uk
Email me with one item at a time for fixes for your project as some of the proceedures might be too long for the forum.
Calvin
www.sjsportscars.co.uk
Email me with one item at a time for fixes for your project as some of the proceedures might be too long for the forum.
Calvin
Mikey: I bought this from a guy who had TEN of them in a barn...!!!
Calvin.... DOH! I'd already seen that site weeks a go and added to favourites, then forgotten about it...
Thanks for the tip! With luck it'll just be good old-fashioned spannering; it's familiarity with the model that's lacking. But not for long...
Ian
Calvin.... DOH! I'd already seen that site weeks a go and added to favourites, then forgotten about it...
Thanks for the tip! With luck it'll just be good old-fashioned spannering; it's familiarity with the model that's lacking. But not for long...
Ian
Jim has a good fix for mirrors. He used motors from another car to fix it.
The slave seals are cheap and are Girling seals, they are made of natural rubber so when relacing fluid it should be Castrol LMA or some fluids have been known to soften and eat seals.
The other stuff is minor. Do you have a manual? If not I can put you in touch with Tim Engel a very good G car Lotus Guru.
Calvin
The slave seals are cheap and are Girling seals, they are made of natural rubber so when relacing fluid it should be Castrol LMA or some fluids have been known to soften and eat seals.
The other stuff is minor. Do you have a manual? If not I can put you in touch with Tim Engel a very good G car Lotus Guru.
Calvin
Recon calipers, I would definately try PNM Engineering on 0151 630 6101. Ive seen some so called recon calipers that other campanies have bodged and PNM have had to redo again. When they do it, you would think it was brand new and I mean brand new!
They also do other recon, reman and used parts to suit all budgets so you give them a try sometime.
You didn't mention what year and model you have bought unless you've mentioned it on another post.
Cheers,
Dave WAlters
They also do other recon, reman and used parts to suit all budgets so you give them a try sometime.
You didn't mention what year and model you have bought unless you've mentioned it on another post.
Cheers,
Dave WAlters
You didn't get you car from a guy called Nick did you ???
It sounds like your car is in a similar state to mine when I got it.
Hmmm, the drivers seat on mine wasn't bolted in either ????????
The mirror solenoid mechanisms have probably siezed, I junked the OEM units and fitted Audi 80 mirrors.
The handbrake cables on mine has rusted internally so jamming up on one side. The cables rub on the chassis and wear through the plastic sleeve hence letting the water in. You will probably find you need new cables.
The heater vac pipe have probably come off under the dash somewhere which is where they all link together.
OK, answers
1. Overhaul rear calipers. Is there a service kit?
Yeap, bit of an arse to fit but straight forward.
2. Strip front suspension (dampers look iffy). Blast and powder-coat all parts. Renew all bushes. Overhaul steering rack.
The hardest bit of this job is getting the mounting bolts out as they tend to corrode. Pressing in the bushes is tricky (I bent the first one in the press) but straight forward. I found using a large bolt and large sockets better than a press as it stops the whole lot twisting as the bush goes in.
Also have a look at the rear bushes as these take a bit of a pounding and if the fronts neede repalcing then it is a fair bet the rears need it also.
3. Replace brake lines as appropriate.
Easy job if you have the pipe tools.
4. Fix blowing exhaust.
Mine has the SS manifold and blows at the collector joint also. It should pass the MOT, mine did.
5. Fix indicators, horns, fans.
Simple.
6. Clutch slave cylinder: replace seals or fit new cylinder? If so, cheap supplier of same (in the UK)?.
Don't bother re-sealing it, just buy a new one as they are only £35. I did the seals on mine and it let go on route to a wedding reception (girl friend NOT impressed) so ended up replacing the whole thing. Get the SS clutch hose line while you are at it (£35) as it is easy to swap out and is well worth it.
I usually get my pars from SJ Sportscars, good service and the owner Steve knows his stuff.
If you wan't to have a look at what I did with my S3 (including most of the jobs you have mentioned) have a look here :-
www.lotusespritworld.co.uk/EOwners/Hill.html
Good luck
Andy
>> Edited by hilly on Thursday 12th February 09:11
It sounds like your car is in a similar state to mine when I got it.
Hmmm, the drivers seat on mine wasn't bolted in either ????????
The mirror solenoid mechanisms have probably siezed, I junked the OEM units and fitted Audi 80 mirrors.
The handbrake cables on mine has rusted internally so jamming up on one side. The cables rub on the chassis and wear through the plastic sleeve hence letting the water in. You will probably find you need new cables.
The heater vac pipe have probably come off under the dash somewhere which is where they all link together.
OK, answers
1. Overhaul rear calipers. Is there a service kit?
Yeap, bit of an arse to fit but straight forward.
2. Strip front suspension (dampers look iffy). Blast and powder-coat all parts. Renew all bushes. Overhaul steering rack.
The hardest bit of this job is getting the mounting bolts out as they tend to corrode. Pressing in the bushes is tricky (I bent the first one in the press) but straight forward. I found using a large bolt and large sockets better than a press as it stops the whole lot twisting as the bush goes in.
Also have a look at the rear bushes as these take a bit of a pounding and if the fronts neede repalcing then it is a fair bet the rears need it also.
3. Replace brake lines as appropriate.
Easy job if you have the pipe tools.
4. Fix blowing exhaust.
Mine has the SS manifold and blows at the collector joint also. It should pass the MOT, mine did.
5. Fix indicators, horns, fans.
Simple.
6. Clutch slave cylinder: replace seals or fit new cylinder? If so, cheap supplier of same (in the UK)?.
Don't bother re-sealing it, just buy a new one as they are only £35. I did the seals on mine and it let go on route to a wedding reception (girl friend NOT impressed) so ended up replacing the whole thing. Get the SS clutch hose line while you are at it (£35) as it is easy to swap out and is well worth it.
I usually get my pars from SJ Sportscars, good service and the owner Steve knows his stuff.
If you wan't to have a look at what I did with my S3 (including most of the jobs you have mentioned) have a look here :-
www.lotusespritworld.co.uk/EOwners/Hill.html
Good luck
Andy
>> Edited by hilly on Thursday 12th February 09:11
Superdave: I'm hoping the calipers just need a bit of a service. They're not exactly rocket science after all
The car is a late '83 S3 in black (plus muck), with, er... yellowy-beige interior (probably known as 'magnolia' or something. Fairly hideous and looking its age, but complete and actually in better order than first inspection would suggest.
Hilly (Andy): Handbrake cables appear in good order and aren't seized. It's the o/s handbrake lever pivot that's stuck. The hydraulics are working OK so it must be something daft.
Suspension bushes: I can only really see that the ARB bushes are tired, and the top balljoint rubbers are perished which is an MOT fail even if they aren't worn.
So if I'm going to wade in there, I may as well do the job properly (time is not a problem, I have a TVR to take out for a thrash if the going gets tough ) - some areas of the brake lines are rough as well, so might as well get the whole thing to bits.
Know what you mean about corroding bolts: the TVR has given me similar grief. I have a 10-ton press and a big vice as backup...!
The car has been stood for two years so maybe the clutch seal rubbers took offence at being used suddenly. There's still a bit of fluid in the reservoir but most of it is down the transmission, so I guess the leak has only just appeared. I'll strip the cylinder and mike it up to see whether a seal kit is viable...
Just got back on, incidentally: I installed a new motherboard, CPU and RAM on the PC last night and it's been tits-up ever since. Just about got normal service resumed after about a million Windows restarts... but that's a tale for another forum!
Ian
The car is a late '83 S3 in black (plus muck), with, er... yellowy-beige interior (probably known as 'magnolia' or something. Fairly hideous and looking its age, but complete and actually in better order than first inspection would suggest.
Hilly (Andy): Handbrake cables appear in good order and aren't seized. It's the o/s handbrake lever pivot that's stuck. The hydraulics are working OK so it must be something daft.
Suspension bushes: I can only really see that the ARB bushes are tired, and the top balljoint rubbers are perished which is an MOT fail even if they aren't worn.
So if I'm going to wade in there, I may as well do the job properly (time is not a problem, I have a TVR to take out for a thrash if the going gets tough
) - some areas of the brake lines are rough as well, so might as well get the whole thing to bits. Know what you mean about corroding bolts: the TVR has given me similar grief. I have a 10-ton press and a big vice as backup...!
The car has been stood for two years so maybe the clutch seal rubbers took offence at being used suddenly. There's still a bit of fluid in the reservoir but most of it is down the transmission, so I guess the leak has only just appeared. I'll strip the cylinder and mike it up to see whether a seal kit is viable...
Just got back on, incidentally: I installed a new motherboard, CPU and RAM on the PC last night and it's been tits-up ever since. Just about got normal service resumed after about a million Windows restarts... but that's a tale for another forum!
Ian
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