S1 Elise idiot's front-end refresh
Discussion
After buying my Elise last year, I've driven several thousand pointless miles, done driver training days, and generally loved every second of it.
Since then, things have started wearing out. I'm nowhere near as mechanically inclined or talented as 99 per cent of you guys on here - I certainly can't weld or anything like that, and didn't even have half the tools until I bought my Elise. Part of the reason I wanted the Lotus is because it's a simple car, however, so I can try to do things myself. Gives me summat to do! Anyway, inspired by the likes of Esprit (George) and his mentalist Exige thread (which I really hope he doesn't give up on), I decided I'd have a tidy up of my car. Starting off with the track rod ends...
In a bid to change a track rod end, the car slipped off my trolley jack in the rain, and the jack went through the sill! D'oh. This one I didn't fix myself, or even try, as I want the body work to be spot on. So the sill was patched up at a bodyshop, and then both sills were painted (as I'm a bit anal about both sides of the car matching!). Top job though, immaculate paint work.
Still, once that was out of the way – (lightening my wallet of £700 after a few other bits and bobs), I had my Elise serviced and found a few other things that needed doing. Mainly the radiator, which was leaking from the plastic end caps. Bit annoying, as the fan was changed just a year ago – so it's a shame the owner didn't sort out the radiator at the same time.
Still, it'd be easy – nobody would put on all the old bolts, would they...
Hmm. Perhaps they would. Lots were suffering from surface rust – but at least 6 or 7 bolts had to be drilled or cut out – one reason I was happier to be doing myself (the receipt for changing the rad fan came in at £1250, over a grand of which being labour on the half arsed job of removing the clam and putting it back with a bunch of knackered bolts...
The problem with drilling the bolts, is that lots were bloody inaccessible. Like this one, just inside the wheel arch. It just turned aimlessly, apparently not fixed to anything but without letting you remove it – a problem I found again and again with this car. So had to cut a small hole at the front of the sill, stick a cable tie in to get hold of the bolt to prevent it dropping into the sill when the head was cut off, and then plug the hole again later:
Clam was then off, but next problem was the clip holding the radiator hose. Was too close to the rad, there was just no way of getting at it with the hose in place, ended up hacking at it with a dremel for about an hour until it was no more!!
![](http://thumbsnap.com/sc/5wCtK2IZ.jpg[/img]</a> <a href="http://thumbsnap.com/VrCDXI2e" Target="_blank">[img]http://thumbsnap.com/sc/VrCDXI2e.jpg)
As you can see though, all the fittings (for the brand new fan) were the 11 year old ones, and rusted to buggery. Again they just turned, without undoing. So again with the dremel...
New radiator and new fittings. I bought new stainless steel fittings for the entire car, so none of the old bolts are going back. Everything covered in copper grease to also make it easier should I need to remove the clam again in the future.
The more I took off, the more I noticed was rusty. The grill was just surface rust, so was cleaned up, covered with coats of hammerite, and liberal coatings of black paint on both sides. I also ordered some new door springs, and a new toeing eye, as mine looked like something that went down with the Titanic. It did mean taking the door off as well though, which considering I'm a mechanical numpty, it was all getting a bit worrying!
Bits of car taking over the garden...
Shiny new bits in place, lots of copper grease around all the new bolts as well.
New radiator fitted and plugged in. Took ages to flush out all the coolant, and didn't do one of the clips up tightly enough, so had to stop to buy a screwdriver on the way down to London!!
And car all back together again. I cleaned it as well!!! And fitted Yoko LTS tyres, which are amazing.
That's it for now though. Clutch needs fixing next. Will get there eventually!
Thanks for reading, thought I'd share anyway!!
Philip
Since then, things have started wearing out. I'm nowhere near as mechanically inclined or talented as 99 per cent of you guys on here - I certainly can't weld or anything like that, and didn't even have half the tools until I bought my Elise. Part of the reason I wanted the Lotus is because it's a simple car, however, so I can try to do things myself. Gives me summat to do! Anyway, inspired by the likes of Esprit (George) and his mentalist Exige thread (which I really hope he doesn't give up on), I decided I'd have a tidy up of my car. Starting off with the track rod ends...
In a bid to change a track rod end, the car slipped off my trolley jack in the rain, and the jack went through the sill! D'oh. This one I didn't fix myself, or even try, as I want the body work to be spot on. So the sill was patched up at a bodyshop, and then both sills were painted (as I'm a bit anal about both sides of the car matching!). Top job though, immaculate paint work.
Still, once that was out of the way – (lightening my wallet of £700 after a few other bits and bobs), I had my Elise serviced and found a few other things that needed doing. Mainly the radiator, which was leaking from the plastic end caps. Bit annoying, as the fan was changed just a year ago – so it's a shame the owner didn't sort out the radiator at the same time.
Still, it'd be easy – nobody would put on all the old bolts, would they...
Hmm. Perhaps they would. Lots were suffering from surface rust – but at least 6 or 7 bolts had to be drilled or cut out – one reason I was happier to be doing myself (the receipt for changing the rad fan came in at £1250, over a grand of which being labour on the half arsed job of removing the clam and putting it back with a bunch of knackered bolts...
The problem with drilling the bolts, is that lots were bloody inaccessible. Like this one, just inside the wheel arch. It just turned aimlessly, apparently not fixed to anything but without letting you remove it – a problem I found again and again with this car. So had to cut a small hole at the front of the sill, stick a cable tie in to get hold of the bolt to prevent it dropping into the sill when the head was cut off, and then plug the hole again later:
Clam was then off, but next problem was the clip holding the radiator hose. Was too close to the rad, there was just no way of getting at it with the hose in place, ended up hacking at it with a dremel for about an hour until it was no more!!
As you can see though, all the fittings (for the brand new fan) were the 11 year old ones, and rusted to buggery. Again they just turned, without undoing. So again with the dremel...
New radiator and new fittings. I bought new stainless steel fittings for the entire car, so none of the old bolts are going back. Everything covered in copper grease to also make it easier should I need to remove the clam again in the future.
The more I took off, the more I noticed was rusty. The grill was just surface rust, so was cleaned up, covered with coats of hammerite, and liberal coatings of black paint on both sides. I also ordered some new door springs, and a new toeing eye, as mine looked like something that went down with the Titanic. It did mean taking the door off as well though, which considering I'm a mechanical numpty, it was all getting a bit worrying!
Bits of car taking over the garden...
Shiny new bits in place, lots of copper grease around all the new bolts as well.
New radiator fitted and plugged in. Took ages to flush out all the coolant, and didn't do one of the clips up tightly enough, so had to stop to buy a screwdriver on the way down to London!!
And car all back together again. I cleaned it as well!!! And fitted Yoko LTS tyres, which are amazing.
That's it for now though. Clutch needs fixing next. Will get there eventually!
Thanks for reading, thought I'd share anyway!!
Philip
Edited by pthelazyjourno on Saturday 26th March 13:15
Thanks guys 
Yeah, very happy that nothing went wrong! None of it was particularly difficult - just time consuming. It's just crazy how much you can spend on labour for relatively simple jobs - a grand to change the radiator etc...
So figured it was worth a go - nice to see the temperature sitting at a stable 87 degrees and it not spewing out coolant after my efforts!
It'll still be serviced at a specialist though. Just quite happy that it gave me a chance to get rid of lots of old bolts and fittings + know that it's that little bit better because of it.
Yeah, very happy that nothing went wrong! None of it was particularly difficult - just time consuming. It's just crazy how much you can spend on labour for relatively simple jobs - a grand to change the radiator etc...
So figured it was worth a go - nice to see the temperature sitting at a stable 87 degrees and it not spewing out coolant after my efforts!
It'll still be serviced at a specialist though. Just quite happy that it gave me a chance to get rid of lots of old bolts and fittings + know that it's that little bit better because of it.
Good job. Did the same rad swap on my VX220. It's a weak point on the elise variants, it will go at some point....
It's a Renault 4 radiator from old tooling, designed to be vertical. In the elise it's mounted horizontal, and always springs a leak from the plastic end caps. The all allot ones (no plastic end caps) are much better. Pretty poor.
It's a Renault 4 radiator from old tooling, designed to be vertical. In the elise it's mounted horizontal, and always springs a leak from the plastic end caps. The all allot ones (no plastic end caps) are much better. Pretty poor.
Thanks people
On the plus side, I also came out of it with a new socket set, new drill and other bits and bobs - and still for hundreds less than the labour would have cost. Plus I feel a bit more confident about tackling things myself in the future - can always get it towed to the garage if I get stuck!! I also had a lot of help from one of the chaps off SELOC - we nearly managed to get the clam off between us on a previous occasion only to be stopped by a couple of bolts - so it was a pretty familiar routine when I did it myself.
Apparently the Dino was Julian Thompson's main inspiration when designing the S1, but it's nice to see a family resemblance to older Lotus' as well.
I just love them, Lotus doesn't seem like any other marque. The (non car loving) public seem incredibly fond of them. I always get let out at junctions, people smile, random strangers chat in petrol stations or even at traffic lights. Perhaps because they're small and not threatening? Or because they're classically styled? Either way, I get a worrying amount of small boys nearly riding into lamp posts trying to look at it when going by on bikes!!.
On the plus side, I also came out of it with a new socket set, new drill and other bits and bobs - and still for hundreds less than the labour would have cost. Plus I feel a bit more confident about tackling things myself in the future - can always get it towed to the garage if I get stuck!! I also had a lot of help from one of the chaps off SELOC - we nearly managed to get the clam off between us on a previous occasion only to be stopped by a couple of bolts - so it was a pretty familiar routine when I did it myself.
Breadvan73 said:
The car looks excellent. The photos bring home the family resemblance to the original Europa.
Thanks. Funnily enough I was thinking similar the other day, looking at one of the Europa threads on here. It's a clever design really - integrating the grill and indicators and such - into a car with completely different styling, without it looking like bits have been pointlessly grafted on. Apparently the Dino was Julian Thompson's main inspiration when designing the S1, but it's nice to see a family resemblance to older Lotus' as well.
I just love them, Lotus doesn't seem like any other marque. The (non car loving) public seem incredibly fond of them. I always get let out at junctions, people smile, random strangers chat in petrol stations or even at traffic lights. Perhaps because they're small and not threatening? Or because they're classically styled? Either way, I get a worrying amount of small boys nearly riding into lamp posts trying to look at it when going by on bikes!!.
grenpayne said:
Good stuff 
I'd love to do stuff to my cars, but have zero experience and knowledge - I've always taken the easy way out and paid garages to do it. It does show it can be done and the money you've saved is staggering!
Even with the Caterham?! I guess at least labour should be pennies, I'd imagine you can access anything within minutes. I'd love to do stuff to my cars, but have zero experience and knowledge - I've always taken the easy way out and paid garages to do it. It does show it can be done and the money you've saved is staggering!
W00DY said:
Great work, it looks awesome!
Can't imagine how gutted you must have been when the jack went through the sill.
Thanks! I've had a few accidents in my time, but the noise a jack going through fibreglass made is the most horrific car-related sound ever! Genuine idiot moment - save £50 changing a TRE myself, spend £700 getting it fixed!!! D'oh. Still, live and learn and all that. Can't imagine how gutted you must have been when the jack went through the sill.
Edited by pthelazyjourno on Thursday 24th March 21:59
pthelazyjourno said:
grenpayne said:
Good stuff
I'd love to do stuff to my cars, but have zero experience and knowledge - I've always taken the easy way out and paid garages to do it. It does show it can be done and the money you've saved is staggering!
Even with the Caterham?! I guess at least labour should be pennies, I'd imagine you can access anything within minutes. I'd love to do stuff to my cars, but have zero experience and knowledge - I've always taken the easy way out and paid garages to do it. It does show it can be done and the money you've saved is staggering!
First plan is to get a decent set of tools then start on the little jobs and work up.
Great little write up. I used to get right involved with my car mechanics proper stripping things down etc, Ive got to admit now im a little older I hate having to dismantle cars to bits if ive a time limit, just in case something else went wrong or snapped/sheared and i'd have to order something in etc. Much prefer to do as a spare/weekend car. I tend to take a week or work just to do a small job, lol, just in case.
Anyway, you did well, can't wait to get me an S1 Elise!
Anyway, you did well, can't wait to get me an S1 Elise!
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