Thanks for the kind words, just used what I had lying around.
Last weekend I had a AWD mach E to try for the weekend, probably the first really viable electric vehicle I have driven, very quick, reasonably refined, but didn't really do much for me. I was happier back in the range rover!
Work has been busy all week so only got back onto the Lotus tonight.
I have decided to make new radiator support brackets which also carry the cooling fan.
Supringly the bolts for the originals came undone.
New longer ones in place.
After this I welded some tabs on for the fan and painted it.
Brackets are all painted and ready to go on, before the radiator can go in I needed to try and stem some of the engine oil leaks, most of it is coming from between the head and front cover, this is my fault because I changed the water pump without removing the head and the sealer I used was an anerobic one not suitable for filling a gap. Long term I might pull the head but could lead to enourmous expense so for now I am going to try and stem the flow by applying sealant externally. So today I cleaned it all up.
Tomorrow I will give it a final clean with brake cleaner then seal it. In the meantime I started making the fan bracket, anealed some alloy and using my now foot operated shrinker.
Made 2 of these.
They will be riveted to bars to mount the fan like this.
Thought I would do a bit more on the Lotus at lunchtime, I applied some sealer to the front cover, they are never that oil tight so hopefully it will stem the worst of it.
I then noticed one of the earth wires on the drivers side had broken, the insulation was also cracked where it entered the loom, one thing led to another and it soon looked like this.
Stripped all the tape off no major issues beyond the damaged earth wire, but the original ignition wiring was pretty brittle and black from corrosion. I usual Lotus fashion the coil was originally in front of the radiator where water drained onto it, after it let me down one day I moved it to up high in the engine compartment and added new wiring, so this can be cut out and removed.
That led to another issue, I decided to cut out the wire which originally bi-passed the ballast when cranking (no ballast now), that made me decide to move the starter cable to a better routing, but when I tried to undo the nut.
The water from the windscreen drains over this!.
Fortunately I had a spare so with some terminals swapped I had this.
Then needed to get back to work but I do need to order a new one of these this afternoon.
Hopefully get some time to clean things up splice in a new earth and re-wrap the loom later then I can get back to the radiator.
Picked up and fitted the last few bolts today, then looking at it I was worried the brackets on the end would touch the bonnet so I re-fitted it, good news is it clears the brackets, bad news is it hits the radiator cap. This is strange because I had measured this several times and it was exactly the same as the original, then the penny dropped, looking at the bonnet lid, the original also touched the bonnet lid the foam seal being compressed to virtually nothing!
I could just put the foam strip back in and live with it but given there is a good 15mm of free space under the radiator I think I will take it all out and slot the mounting holes. I suspect originally they pushed it as high as they could to keep the water level up in the head, Many years ago though I fitted a remote reservoir much higher up at the back so this will be fine for me.
Another option would be to cut the cap off and get someone to weld it up, but I guess that is going to cost a fair bit. so the radiator will drop, hopefully I'll get a chance tomorrow.
Bonnet now fits fine,pic is with no hinge pins and its about 1/2" underflush now.
That gave another problem, top hose is very close to cam cover.
So I dug out a few hoses from my collection.
With the bend off of one of the hoses on the radiator, back to a sensible clearance
Just need to get a 33mm joiner now.
Bottom hose also turned up even made in the UK, old one was a bit swollen.
Then i got carried away again, the wires for the lumenation have always been trapped under the air intake pipe, someone had fitted protection but it was far from ideal and was wearing the body away.
If I move it along 6 inches there is plenty of clearance under the air cleaner, so off it came leaving loads of redundant holes, so these were run down with a countersink.
Filled in with a flexible filler.
And prepped for a coat of paint.
This is where I had to stop, the aerosol of paint is blocked.
Most of these jobs are things I have been meaning to do for the 25 years I have owned the car, working from home and being able to spend 2 or 3 lunch hours a week on it has finally got them done, only thing left now is to try and improve the heater, many years ago I fitted a more powerful (mk2 fiesta) fan but that has always been noisy and there are some really powerful small axial fans out there now which should work much better. It also doesn't get much heat at low speeds, I think the very small crank pulley means the pump isn't moving much at low engine speeds, might try a auxiliary pump in the heater circuit, If all else fails It may mean taking the dash out and fitting one of the modern aftermarket ones.
Turned up a brass spacer from a bit of hex bar to replace the fuel tank banjo.
Fitted that, painted and reassembled the rh engine compartment.
Dragged out my ancient jerry can and bought 20L of 99 octane.
With that in it fired up easily, just need the joiner for the top hose and a few bits of interior trim re-fitting to finish now.
I then dragged out my old gunsons gastester mk2, it seems to work still so used it to set the range rover up, seems it was much too weak, set it to 1.5%, we'll see how it goes now.
Finaly dragged this out of the back of the shed where it has been for 3 or 4 yesrs.
It's a bit of a sore point, my wife asked me to get a new pressure washer, as you would I got the most powerful (5.5hp) dino juice fuelled one I could find for the budget, apparently she meant some nice looking sweet smelling tidy looking plastic cased electric one!
Stuck some fresh fuel in it and it started first pull.
Anyway we've got it now so sometime in the week I will be cleaning the patio and paths.
Been busy with work but managed to get a few things, firstly the fuel I put in started dripping out of the bottom, turned out a few strands of the felt the tank sits on had got under the sealing washers, it's a right pig to get to but in the end I got it out and sorted it all dry now.
Hose joiner arrived for top hose was fitted and it filled with coolant. With that I got it out and gave it a wash.
Front wing is still gun finish and the bottom flange of the sill needs painting black , but that's about all. Inside the under dash trims needs fitting and the vinyl is peeling off the centre console but they should be easy lunchtime jobs.
After a wash I took it for a drive, much better to drive with the new throttle return spring but it did fail to proceed as I returned home, turns out I had forgotten to tighten the fuel pump earth screw so easily fixed, with that done all seems well, another nice problem to have is that in today's ambient with the new radiator it doesn't get hot enough to test the fan.
I’m a big fan of your fleet and your innovative approach to repairs and improvements. I fully concour with the above except that exhaust! - it’s in need of a little blue pill!
Yes I looked at the photos and spotted that straight away, It was pointed down to stop fumes coming inside but didn't make any difference, I'll have to measure it up and order a new piece of stainless pipe.