Elite restoration begins!

[Pete Boole]

Thanks Peter. Once the diff is done I can start hanging some suspension off it!

Pete

[Pete Boole]

So - now I can hang some stuff off the diff I thought I'd start with rebuilding the drive shafts. The common answer to "what are the strongest U/Js" seems to be Hardy Spicer 163 (HS163). When you see them side-by-side with a standard U/J they are obviously much stronger (they are heavy-duty Land Rover items):





The problem however is that they do not fit!! . At least they do not fit into all the yolks of the driveshaft: They fit into both ends of the driveshaft itself, and some of the outer driveshafts (that fit into the hubs), but none of the diff flange yolks . You need 59mm between the yolk arms for the larger HS163 to slide in.
Undeterred (after some choice language ) and having already bought the U/Js, I went straight into the shed and fired up the milling machine . This is the result:



The arrows show where the diff flange has been machined to make the distance between the yolk arms 59mm. Only 0.040" needed to be removed from each side (I used a ball-nosed cutter to minimise any sharp changes in radius). The HS163 now slips in perfectly. I do not believe that I have significantly reduced the strength of the flange as it is already thicker in this area than the other yolks in the driveshaft assembly. Definitely worth the effort/risk for the better U/Js. Time will tell

Pete

[Lotus-e-Clan]

That's worth pointing-out and makes a lot of sense Pete. It's is certainly consistent with my experience.

It makes no sense to fit U/J's with a reduced journal surface area on an Elite/Eclat. The Elite /Eclat drive shafts are multifunctional (drive + primary suspension location) therefore u/J's take a hammering.

To further illustrate the point ....the Clan's springs and dampers were specified by Lotus engineers, and typically they went for long /soft springs which give the signature Lotus ride/handling compromise. The downside is that the standard Clan eats U/J's and doughnuts (compared to their Imp cousins) because of the resultant extended driveshaft articulation with Lotus specified long soft Lotus springs and dampers.

And to prove the point, my modified Clan currently has short / stiff springs with limited damper travel which results in reduced driveshaft articulation but provides almost infinite U/J doughnut service life compared to the Lotus-specified suspension. The ride and handling on rough B roads with short stiff springs suffers greatly but every cloud has a silver lining (extended u/j and doughnut life).

So fit the best u/J's you can find to a Lotus Elite /Eclat if you want a reasonable service life - or be prepared to renew the U/j's annually for the MOT(if used as a daily ) if you fit crap items.

[Hawaiis0]

You got 10 weeks

Are we due/allowed any new pictures yet?

[Pete Boole]

You got 10 weeks

Are we due/allowed any new pictures yet?

I've recently finished the special "low profile" hoist installation in the garage - it allows me to lift the body shell vertically off the ground far enough to slide the chassis under it - all in a modern low-ceiling garage. I'll post some pics soon. I've been posting a Delanair aircon refurb/reworking on "the other forum " as I thought it would be more useful over there - more Elite/Eclat owners over there?

Maybe we could do with a "Projects/Restorations" section on here

Pete

[DavidOliver]

Pete, on U/J´s
Your photographs show how the used U/J has suffered hammering of the needle roller on an almost fixed part of the trunnion, which is a result of wheel/road bump hammering. The needle rollers do not rotate around the trunnion as you normally get on a rotating bearing such as wheel bearing.
Consequently any strengthening of the U/J is highly recommended as you have indicated.

Add to this the very exposed location of the Elite U/J´s to rain and salt, and possibly early non-greasable U/J´s and you have the recipe for trouble.
You might consider installing a leather weather spat around the U/J.

The U/J´s on my Elite which I had in 1980´s failed some 10 km out of Calais on my way back to Spain from UK, requiring a slow drive back to the Ferry, foot passenger to London for new U/J´s and a hammer, back to Calais and a two hour roadside fix.
When you buy an Elite besides the cambelt you need to change the U/J´s, particularly if you live away from rapid parts suppliers.

Dave the cog.

[Pete Boole]

I've not considered adding a boot of some sort - what a good idea Dave . I'll look into that. You used to be able to buy split CV joint boots at one time - I wonder if stuff like that still exists? The old Jags used a sort of clip-on steel "bowl" around the joint. I wonder if I could combine something like that with maybe a CV joint boot on the opposite side of the joint. Dammit - more research!!

Pete

[Pete Boole]

Glacial progress! However, I dismantled the steering rack today - it's a Burman - same as the Ford Capri I believe. This is all that was left of the nearside plastic bush:



I think I'll replace it!!

Has anyone refurbished their rack using the kit from Lotus Marques in Australia? Their kit includes better pinion bearings (tapered roller instead of the original angular contact) that are supposed to improve the rack no end. Waiting to hear from them re postage costs.

Pete

[Pete Boole]

Postage £25 from Australia so I've ordered a rack overhaul kit. It will be interesting to see how the bearings differ.

Pete

[Pete Boole]

First test of home made body lifting kit today. It needed to be very low profile as I work in an ordinary garage with very little height. Worked well. Because I'm not using the original chassis I needed to re-drill all the mounting points on the replacement chassis, so the body needed lifting on and off the chassis several times to get all the holes in the right place. The lifting kit made it easy to raise and lower the body quickly and safely. Having done this I can now start building the rolling chassis







Pete

[Hawaiis0]

Absolutely brilliant Pete. Usual standard

[Pete Boole]

Cheers bag! Are we still allowed to use your Old Name??

Pete

[Hawaiis0]

I've been modified some how. Not my doing so I need to get it sorted. However the stealth mode is interesting

[Pete Boole]

Good avatar though!

Pete

[Tanz]

Wish I had your garage Pete. Still got that kylie calendar up! Rain has stopped play on the M100 today. Lift looks great. You are making good use of this retirement malarkey!