New member - Excel SA

Restoration threads may be posted here. I can move them from any other topic if you wish.

Moderator: Board Moderators

Pete Boole
Senior Poster
Posts: 3158
Joined: Tue Apr 04, 2006 21:28
Model: Elite
Colour: Monaco White
Year: 1974
Location: Nottingham

Re: New member - Excel SA

Post by Pete Boole »

Those seats look great Neil and will probably be much more supportive than the Excel ones which aren't great to be honest. Good find! I'm going to check out some black ones now :D

Pete

User avatar
Excel SA
Senior Poster
Posts: 430
Joined: Thu Jul 02, 2020 06:11
Model: Excel
Colour: White
Year: 1987
Location: Johannesburg, South Africa

Re: New member - Excel SA

Post by Excel SA »

The seat installation has been covered on a separate thread: viewtopic.php?f=36&t=12520

Other progress - the new air intake system is almost complete - some minor bits left to do still - but here it is mounted to the upper radiator duct:

Image

Another angle - the green arrow is where I added in a fiberglass angle to strengthen and stiffen the front edge of the duct as it was pretty flimsy after the hole was cut:

Image

The angle was also used to make the fixing points for the intake to be held in place - 3 nutserts were used - here I used a saddle for electrical conduit as a mold, and filled it with a resin and microfiber mix to the top of the nutsert - I did use mold release on the saddles, so they just popped off once the resin had cured.

Image

And a view from below, installed in the car. Fixing points and high stress areas were reinforced. The whole unit still needs to be cleaned up and painted. Access from the lower radiator duct still has to be sorted out.

Image

A bit of an issue cropped up when connecting the pipe work to the engine intake - when the bonnet is opened the support bar across the front of the bonnet was touching the silicone hose. I need to install a solid piece of tubing for the MAF sensor, and pushing that closer to moving parts of the engine when opening the bonnet would have been a problem!

Image

To solve the problem I removed the support bar and introduced a bit of a curve into it - I don't see that there will be any other ill-effects by doing this - there will still be some fettling required to get the bonnet and body work lined up nicely.

Image

Neil.

User avatar
bash
Senior Poster
Posts: 1895
Joined: Thu Nov 03, 2005 15:34
Model: Se, V8
Colour: white
Year: 1986
Location: Doncaster
Contact:

Re: New member - Excel SA

Post by bash »

This is probably a dim question from a dim person, but, how are you going to change the air filter at service time.

Bash
On a mission to find the airspeed velocity of a european swallow.

User avatar
Excel SA
Senior Poster
Posts: 430
Joined: Thu Jul 02, 2020 06:11
Model: Excel
Colour: White
Year: 1987
Location: Johannesburg, South Africa

Re: New member - Excel SA

Post by Excel SA »

I did plan for that :lol:

The filter housing comes out, it will need to come out through the lower radiator duct, which I will need to split into 2 to keep the radiator in place. So a few bolts to undo, nothing too major compared to some modern cars....

Neil.

User avatar
bash
Senior Poster
Posts: 1895
Joined: Thu Nov 03, 2005 15:34
Model: Se, V8
Colour: white
Year: 1986
Location: Doncaster
Contact:

Re: New member - Excel SA

Post by bash »

I thought you had a plan.

Cheers
Bash
On a mission to find the airspeed velocity of a european swallow.

Pete Boole
Senior Poster
Posts: 3158
Joined: Tue Apr 04, 2006 21:28
Model: Elite
Colour: Monaco White
Year: 1974
Location: Nottingham

Re: New member - Excel SA

Post by Pete Boole »

Air intake looks great Neil - very professional! I hope you're going to do a sound clip when you get the V8 running :D

Pete

User avatar
Excel SA
Senior Poster
Posts: 430
Joined: Thu Jul 02, 2020 06:11
Model: Excel
Colour: White
Year: 1987
Location: Johannesburg, South Africa

Re: New member - Excel SA

Post by Excel SA »

Thanks Pete, will be a while before there are any V8 sounds....

Here's a pic showing how the air-filter box comes out - once unscrewed it hinges down and into the radiator duct to be removed. There will be a seal between the fixed and removeable section - the gap changes when it is actually installed, compared to when it is out of the car - tightening things up an a fiberglass body means some distortion apparently.

Image

Neil.

User avatar
Excel SA
Senior Poster
Posts: 430
Joined: Thu Jul 02, 2020 06:11
Model: Excel
Colour: White
Year: 1987
Location: Johannesburg, South Africa

Re: New member - Excel SA

Post by Excel SA »

A million jobs done - another million to go.... :D

The oil filler neck on the engine was too long - it would have needed a bonnet scoop all of its own, and we know how those are frowned upon!

I cut a section out and took it to the wheel repair guys up the road who can weld aluminium and had it welded back together:

Image

It needed some work to make it look a bit more standard...another niggly job out of the way.

Image


Put some of the car together, and found that the 3D envisioning section of my brain doesn't work that well - a bit of contact between the air inlet and the radiator fan (the red circle) - this will need extending and a notch built into it to give some clearance.

Image

Spent a good chunk of the weekend on getting the center console/dash sorted - it went in and came out a good number of times whilst things were fettled. A few more minor tweaks and then I can look at getting it all covered. I have bought a radio that is a 1/2 DIN size - no CD player so the body of the radio is quite short - which allows it to fit in the space chosen - a bit higher up in the console, without (hopefully...) hitting any of the plumbing at the back. Yes, the USB port is upside down....There must have been some people with very small hands and great dexterity working at Lotus - getting nuts and washers onto some of the bolts is a challenge.

Image

Neil.

User avatar
Hawaiis0
Senior Poster
Posts: 3763
Joined: Sun Jun 30, 2013 18:39
Model: Excel SA (No 3); Elite 504
Colour: BRG; Dirty White
Year: 1986
Location: West Oxfordshire

Re: New member - Excel SA

Post by Hawaiis0 »

That gear shift is lovely.

User avatar
MetBlue
Senior Poster
Posts: 982
Joined: Sat Mar 24, 2018 21:00
Model: Elite 74 & Excel 92 (SEish))
Colour: Metalic Blue
Year: 1974
Location: Northampton

Re: New member - Excel SA

Post by MetBlue »

Starting to look very co-ordinated. More so than the standard lotus auto selector.
Nice work. Looking forward to seeing it covered.
Tony
What goes together.... Must come apart.

richardw
Moderator
Posts: 1958
Joined: Wed Feb 06, 2013 15:06
Model: Elite S2.2 Automatic
Colour: Essex Blue
Year: 1981
Location: Worcestershire

Re: New member - Excel SA

Post by richardw »

Very nice work Neil.

Cheers, Richard
Image

Pete Boole
Senior Poster
Posts: 3158
Joined: Tue Apr 04, 2006 21:28
Model: Elite
Colour: Monaco White
Year: 1974
Location: Nottingham

Re: New member - Excel SA

Post by Pete Boole »

Great work Neil - going to look really good once it's all covered. As Tony says - better than the Lotus original!

Pete

User avatar
Excel SA
Senior Poster
Posts: 430
Joined: Thu Jul 02, 2020 06:11
Model: Excel
Colour: White
Year: 1987
Location: Johannesburg, South Africa

Re: New member - Excel SA

Post by Excel SA »

Thanks all - a bit of an improvement on version 1 as shown below I think....

The surround for the gear lever is not flat, so everything needs to curve so that it all lines up on the surface.

Image

Neil.

Post Reply