Elite restoration begins!

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Hawaiis0
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Re: Elite restoration begins!

Post by Hawaiis0 »

Excellent work as usual Pete. I'm lining my jobs up for when you finish :D
Umm! What to do next?

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Yes - hardly anything left to do now!!

Pete

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MetBlue
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Re: Elite restoration begins!

Post by MetBlue »

Great work. Like the trunnion mod. Very neat.
What's next on the todo list then?
Tony
What goes together.... Must come apart.

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

MetBlue wrote:
Mon Apr 27, 2020 19:09
What's next on the to do list then?
Probably finish off all the brackets/column etc for the electric power steering.

Pete

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Now the body is on I thought I'd spend some time on the new engine block I bought a couple of years ago for this project. It's a brand new block in a Lotus box but was obviously one of the blocks that should have gone back for re-machining for +0.015" over-size main bearings. The seller would not have known. The problem with it is that two of the main bearing bores are over 0.0015" out-of-round - factory limit is supposed to be 0.0005" out-of-round (although of the blocks I've measured to date I can't see any of them being this good!), and the other bores were far from perfect. I'd got four choices - sell it on, get it line-bored to original spec, get it line-bored for over-sized bearings (these are readily available again) or try to fix it myself. Obviously I'm going to do it the hard way!

I had a tool maker in Sheffield make me up a hardened and ground tool to exactly the smallest main bearing bore size (there is a tiny range that is acceptable) to fit my horizontal milling machine arbor. I used this as a hone with some 10 micron diamond lapping paste to slowly hone the bores round, or at least rounder.

This shows a light shining through the gap below the honing tool :shock:

Image

This is the tool: The spacers on the arbor allow the honing block to be placed over each bearing. The pilot at the far end keeps the tool in line (pilot needed at both ends when honing the centre bearings)

Image

Image

It's worked! :D

What I couldn't predict was whether the bores would all line up, so it was a bit of a gamble, but after two days of slowly honing the block and girdle all the bores are rounder, give the correct clearance, and line up! The crank rotates beautifully smoothly.

Delighted with the result (and saved about £700).

Pete

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MetBlue
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Re: Elite restoration begins!

Post by MetBlue »

Nice work. Very creative thinking.
Must be nice to have the machine tools at you disposal. Very envious.

Tony
What goes together.... Must come apart.

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rbgosling
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Re: Elite restoration begins!

Post by rbgosling »

Pete Boole wrote:
Sat May 02, 2020 18:20
...over-sized bearings (these are readily available again)...
Pete
I wish they were 3 years ago, could have saved me a LOT of grief!!

Very elegant solution Pete, nicely done.
"Farmer" Richard

1990 Lotus Excel SE (Lilith)
2004 Jaguar X-Type Estate

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Thanks guys :D. I thought about your plight Richard when I was researching what to do! The +0.015" bearings are expensive, but at least they are available now.

Pete

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DavidOliver
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Re: Elite restoration begins!

Post by DavidOliver »

Pete, while you are working the block, may I suggest you check the water pump housing for good coolant flow.
In my Elite block I had serious flow restriction from casting burrs, a little work gave at least 30% more flow and solved
excessive coolant temperatures.
You probably have already done this.

Also oil ponding relief on the exhaust cam carrier to avoid gasket leaks. I assume you have saddle type carrier covers.

Dave the cog.

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Thanks Dave. I have already done the coolant thing - there are pictures somewhere in this thread showing the difference between the 907 and 912 blocks. The exhaust cam carrier oil drain holes I haven't done yet - I'm really hoping to find some SE-type cam housings, but they are like rocking horse poo! I'm going to have a few chats with gasket manufacturers after the lockdown to look at modern gasket materials for the saddle-type cam housings as well - I've got a couple of ideas.

Pete

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Bolted the first bit back on today! Woo Hoo!

Image


Image

Pete

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

Not really progress - but just in case I decide to fit some ICE in the car at a later date I've added a couple of flanges to locate a bass drive unit in the area vacated by the vacuum reservoirs:

Image

Pete

Excel SA
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Re: Elite restoration begins!

Post by Excel SA »

Neat fiberglassing there Pete - I'm going to be needing some of those skills!

Pete Boole
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Re: Elite restoration begins!

Post by Pete Boole »

By the time you've repaired all that bodywork you'll have them! :D

Pete

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Re: Elite restoration begins!

Post by Excel SA »

Thanks for the reminder :mrgreen:

Honing my metal working skills right now, avoiding fiberglass.

Neil.

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