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Lotus Europa Forums => Garage => Topic started by: tedtaylor on Wednesday,March 29, 2017, 07:49:41 AM

Title: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Wednesday,March 29, 2017, 07:49:41 AM
Having seen/read Glen's blog posts on his yellow Europa restoration, I decided to do the same.   Actually this goes back to the "other" Lotus forum (LE.net) where Glen covered the restoration of a beautiful red Elan S4 DHC.   I followed suit and started a blog on the "soft" restoration of my '73 Elan Sprint DHC.  It was greatly received.

So in order to share with the group my restoration efforts on my newly acquired JPS#059 from Texas, I'll report/post here the steps i'm taking to make this road worthy once again. 

A little history:  I previously owned JPS#185 and sold it a couple years ago with great regret.   I now came across this JPS#059 right here on this forum and decided to "rescue" it.  It is a two owner car with only 30K miles.  Has a pristine interior.  The original paint is quite dull and needs buffing/polishing.  All the mechanical systems need a going through.  I feel the "soft" restoration process is the only way to go.   Keeping original paint and patina far outweighs the value of a fully restored car, in my humble opinion.

I'll post pictures along the way.   First thing I did was to address the wheels/tires.   I had an additional full set (advertised here for sale previously) and kept the best of them.   I mounted the nearly new Khumo tires and attached the new center caps.  I have inventoried the extra odds & ends parts the previous owner had boxed up and included.

The pictures show the car "as received" or just previous to its transport home.   Notice the absolutely completely original engine bay with all the evap system tanks, vacuum lines, crossover tubes, brake boosters, etc.  Never been botched, chopped or thrown away.   I hooked up a battery, turned the key, and BUZZZZZ, what's that?? the fasten seat belt buzzer sounded!!!  That's a first for me in any Europa i've been in.  All the lights, windows, switches, everything electrical working fine.   It even cranks over.   I polished half the roof to show myself that indeed, this car will shine up like a new penny.    I'm only dabbling around with it and will post on occasion as progress continues.   I'm in no rush to get it done.   I'm hoping others will appreciate seeing the progress on this one.   
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Wednesday,March 29, 2017, 08:44:11 AM
That looks like it will turn out to be a very nice project! I look forward to watching your progress!


 :lotus:
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Bainford on Wednesday,March 29, 2017, 08:55:20 AM
It's clearly in need of some love, but it's a fine project. Looking forward to seeing more.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Wednesday,March 29, 2017, 09:33:22 AM
Ted, glad your documenting for all of us to watch over your shoulder. Can't wait to see progress. We have enough "local" Europa owners that we could do our own driving event! See you on the road soon.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Lou Drozdowski on Wednesday,March 29, 2017, 01:14:57 PM
Ted , Glad to see 059 in the pics, really looking forward to the progress reports...see you soon. ld
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Pfreen on Wednesday,March 29, 2017, 01:27:56 PM
It looks like a good car.  I own 2963R which is not a jps, although it has the five speed and alloy wheels.  I guess they needed to be black to get a jps button.  I have owned mine since 1985.  I am just completing my restoration, ie paint, chrome, interior and upholstery.  Mine was originally regency red with gold  jps stripes.  The paint had a million cracks and flaws in the paint, so you are lucky.

Good luck and have fun!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Thursday,March 30, 2017, 02:34:37 PM
Thought I'd give a shot at a polish/buff on the old dead original patina paint and voila!   See the amazing difference on the roof where I just did half.  The chrome comes up nearly perfect too!  :)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Thursday,March 30, 2017, 02:41:06 PM
There are lots of ways to resize pictures. This is one way Joe recommends: http://www.lotuseuropa.org/LotusForum/index.php?topic=1379.0


I use the snipping tool (available on Windows after 7) - I display the photo on the screen and use the snipping tool to make a copy of the area I want to show and save that to a file. I can use the snipping tool to capture the entire picture if I want because the new resolution of the picture will be the resolution of the screen which will make it "small" enough to attach to your post.


Whatever floats your boat.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Fourporche on Friday,March 31, 2017, 04:52:25 AM
 :lotus:
Could a white 74 with gold stripes TCS
Be a JPS?
I thought they are black only
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Friday,March 31, 2017, 05:06:56 AM
Nice Ted. Should be show worthy after the work your putting into it.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Friday,March 31, 2017, 05:43:10 AM
:lotus:
Could a white 74 with gold stripes TCS
Be a JPS?
I thought they are black only


I'm almost positive all JPSs were black since that livery was a homage to the JPS cigarette package (though I think I remember someone claiming he had or knew of a JPS in a different color). If you're talking about my car, I'm kind of copying the look of the first Europa I had. It was a white four speed TCS with gold stripes and had the JPS sticker on the B pillar (apparently put on at the dealer). I liked the look of the JPS sticker, along with the stripes, so included them both on my current car when I rebuilt it. Maybe I've committed a heresy...
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: brucelotus26r on Friday,March 31, 2017, 07:02:02 PM
Nice car we need to get out and drive them soon. Mine has the seat belt buzzer to I unplugged it.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,May 09, 2017, 01:52:41 PM
Went and bought a new battery for the car today.  Tough fitting it into that small space and getting around the coolant header tank.  Cranks over nice and fast.
Filed the points and now have spark at the points.    Plugs are new and I set the gap according to spec.  I sprayed Gummout 2+2 carb cleaner (in lieu of starting fluid or gas) into the carb throats and cranked it over hoping to hear it run...... with no luck so far.
Still going over things.   I want to hear it run to motivate me to start chiseling away at the very long list of things to do on it.
Cooling system, Fuel system, Brake system......and so on.

UPDATE:  Just went out to garage after dinner, pulled the plugs and shot 2+2 carb cleaner into each cylinder, reassembled, and cranked it over and....... VIOLA!!!!    IT RUNS!!!!!!
sounded great, smooth, no knocks or funny noises, just roared back to life after sitting those many, many years!!!!
NOW I'M PSYCHED! :trophy:
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: jbcollier on Tuesday,May 09, 2017, 04:10:06 PM
You fired it up with fresh oil, right?
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,May 09, 2017, 05:39:45 PM
Congratulations, Ted!


As John said, all new fluids - including gasoline - are certainly in order.


Things seem to be coming together. I share your excitement!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,May 09, 2017, 06:54:34 PM
Yes, oil and filter were changed by PO a year or two ago while in storage.
As usual, one step forward and two steps backward!   I checked the coolant header tank to find the bottom 2 inches a mucky mire of crud, so while cleaning out, sure enough, rusted out on bottom of can.   Have any of you been successful with repairing these?  see First picture
Also, after cleaning the fuel pump filter and glass bowl, this is what was sucked out of the fuel tanks!   Juicy red varnish!  see 2nd picture.   So i'll need to drain the tanks, refill and try again.   I need a new fuel "T" before i'm able to hook up the fuel line to the carbs.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: jbcollier on Tuesday,May 09, 2017, 07:22:51 PM
Cut the bottom off the header tank and braze a new one back on.  You can also buy alloy replacements.

I would pull the fuel tanks and have them hot-tanked and sealed.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,May 09, 2017, 09:37:11 PM
I would also clean out the fuel pump and carbs if needed. Make sure you have a metal 'T' between your carbs. The stock plastic ones crack and dribble gas on your exhaust pipe.


I would also flush out your cooling system and make sure your radiator is in good shape.


Like I said, I would change all your fluids and ensure those systems are in good shape.

Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Wednesday,May 10, 2017, 03:36:59 AM
Congrats on getting it running Ted! Great motivation to get the rest of your list completed. I've got a header tank you can have and two fuel tanks. Give me a call.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Thursday,May 11, 2017, 01:39:10 PM
I drained both tanks and got almost 2 gallons of that old red gas out.   The exit ports are forward/bottom of tank so i had to jack up the rear end of the car real high to drain it good.   I can now see the actual metal bottom of the tanks now, so they're just about completely empty.   The tanks are not original, but replacement aluminum tanks that are very well made and fit as original.  They are 20 plus years old.

I filled with fresh gas, clean filter and cranked it over.   She now runs on its own fuel supply and no leaks.  While running, the oil gauge reads with good pressure.

Now my focus will move onto the cooling system, flushing out, replacing the header tank, checking for leaks.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Thursday,May 11, 2017, 08:38:39 PM
It's a very good sign that you have nice aluminum tanks! Let us know about your progress.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Friday,May 12, 2017, 03:12:51 AM
Amazing that it had Aluminum tanks Ted, as everything else is original. Any chance it came from the factory that way? Glad to hear the engine is running and you have oil pressure.

It's very cool that your Sprint and Europa are original and have that faded Patina.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Friday,May 12, 2017, 05:36:27 AM
Amazing that it had Aluminum tanks Ted, as everything else is original. Any chance it came from the factory that way? Glad to hear the engine is running and you have oil pressure.

It's very cool that your Sprint and Europa are original and have that faded Patina.

Just wait until LEO (of ProOCD) gets a hold of it next month.  It will be shining like new!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Monday,June 05, 2017, 09:31:47 AM
Had some time this morning and started to tackle the cooling system hoses.   I obtained a used header tank from "certified lotus" (thank you Glen) and gave it a quick finish paint job and ready to install.   The car came with a brand new (maybe 15 years ago?) hose set that was never installed, so i'm sorting through, changing out all the hoses.   fun, fun!   Got to get underneath for those connections to the tunnel tubes.   greasy dirty mess.   Very old antifreeze came out of the system with only a slight "hint" of green.  I will need to flush the lines and the radiator good.   
Has anyone "snaked" the tubes in situ?   Some sort of pull line with brush attachment would be ideal.   I'll jury rig something if no one else has a suggestion for cleaning out.   The small metal tube going up to the bottom of the header tank was clogged solid with gunk!!!

After dinner, I went back out to the garage and continued to use a plumber's helper "snake" to ream out the tube.  I was fearful that the snake would poke through the side of the tube just like the header tank rusted through while cleaning that out, but it didn't.   I had great difficulty getting the wider part of the snake through.  It was as if the tube had a smaller inside diameter.  I think in actuality, the weld spots where the tube is connected to the frame disfigured the diameter inside where i couldn't see, but the snake was definitely getting stopped from going through.   Eventually I was successful by pulling it through rather than pushing it through.   What a black dirty greasy mess!
Now to flush out the other BIG tubing through the central backbone tunnel and radiator.   
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,June 06, 2017, 05:34:48 AM
Good job! I was trying to think of something clever to say about the juxtaposition between the pipe wrench that comes in the OE tool kit and the plumber's snake...
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,June 06, 2017, 06:35:38 AM
BDA, i'm sorry that i did not make an effort to meet you at LOG37.   I remember seeing your white Europa w/ BDA engine, but my mind was all over the place.   Would like to have met you.   Sorry i was not more cordial and focused on people rather than their cars.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,June 06, 2017, 09:26:12 AM
Hi Ted,


I'm sorry I wasn't able to catch up with you, too! Which car did you bring? You don't need to apologize though. The cars were pretty much the main attraction and if you saw my car, between it and me, you saw the more interesting. Did you get a chance to peruse the museum? Hopefully there'll be a LOG we can both attend soon (I'm not sure I want to drive to Cincinnati in August in my car! Birmingham is the outer limit of how far I want to go in my car during the summer months!)!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,June 06, 2017, 10:05:09 AM
BDA - I drove down in my M100 Elan.   Wanted to take the Elan Sprint, but just too far.   Of course, the JPS Europa is not ready yet.   Yes, did the museum too (both rocket & space center, as well as Barbar)

Back out in the garage again today working on the cooling system flush.   What a very dirty WET mess indeed.  While i'm replacing the coolant hoses with the replacement set provided, i'm seeing very original wire band clips and original hosing for the heater system too, so i might as well replace that all at the same time while i'm under there getting access and dirty at the same time. 

I tried flushing the heater lines and not getting any luck getting the stream of water through the lines with my garden hose, even with high pressure.  I'm hoping i don't have a blockage or plugged up heater core!    Looks like i'm gonna have to go in the cabin to change out the heater hoses there too - all the while, not trying to get the interior wet!
FUN FUN!!!

I just finished up in the garage after a full day out there flushing (not the toilet) :D
I was able to unclog the heater core piping and fully flushed the heater core and tubing in the center tunnel for the heater lines.  Everything is now flushed fully (engine - even pulled the drain plug out of the block, radiator, tunnel tubes, and heater core).   I bought 1/2 tubing for the heater hoses, but found that they are special shapes to do the 45 degree bend.  Found them on Rdent and ordered same.  When they come in, i'll start the reassembly.

This car had all original hoses and pipe clamps.   I have replacement clamps, but the newer band style.   Now i'm wondering if i should replace the same wire hose clamps to maintain originality??   It's not like I'm competing for a National First prize or anything, but yet i do like to maintain originality.  Updated clamps can't really be a negative on an original car, can they?   At least the next owner can readily see that the hoses have been updated and replaced - seeing the newer style hose clamps.   Decisions, decisions...
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,June 06, 2017, 10:32:55 AM

That is a pretty messy job. Even if you weren't having these problems, if your car had been sitting up for any length of time, it would make sense to have your radiator and heater core inspected. I might go with a new aluminum radiator anyway. You may want to consider a heater on ebay at the moment. It looks in pretty good shape.



Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Tuesday,June 06, 2017, 02:35:42 PM
Ted, your doing all the important stuff, making sure the cooling system functions well. Tony Thompson personally told me that next to rebuilding the engine the cooling system is an absolute must to clean and have working properly.

You will your Europa on the road way before mine. Maybe in the later fall we can go for a drive together.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Bainford on Thursday,June 08, 2017, 08:35:52 AM
You are doing some good and thorough work here. Your Lotus will love you for it.

I would definitely replace the hose clamps with something reliable. You are by now well aware of how many of them there are on a Europa cooling system, and some of them are difficult to access. In my personal opinion, if you plan to use your car for regular or occasional road use, reliable clamps are a must. I would think that on a driven car, this concession from originality would be deemed acceptable by the wider Lotus community.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Friday,June 09, 2017, 03:37:12 PM
spent the day installing all the new hoses.   It took several hours!  Access being the biggest challenge, but also trying to be methodical and fit everything properly and tighten clamps to avoid any future leaks!   The clamp set the Previous Owner had bought had a few the wrong size, so i had to scurry around finding the right size clamps to use.

So the moment came, the hoses installed, so time to fill with water.  I wanted to use a "clean flush" product and thought i had one laying around.....wrong!   So for now just to test the system for leaks, I filled with water.   Started engine and let it warm up, then....   Further gremlins found!!!

1) the heater core and hoses to/from never got warm so something is blocked.   I know i thoroughly flushed every tube and the core itself, so something else is wrong here.   The previous owner also bought a new heater valve, so i suspect the original, altough moving externally, I cannot determine whether it is moving "internally".    So I'm thinking that heater valve is either clogged or broken or stuck closed internally.   I'll replace that another day.

2) The temp gauge was working and it never got real hot to turn the cooling electric fan on, so i was not able to test the fan, whether it works or not.   I'll have to figure out how that works.  The two wires going to the temperature sensor on the radiator have juice/electric, but i need to further research how that makes the fan work or not.

3) another gremlin - while the car was running, i noticed both left and right turn signal indicators were lit on the dash, as well as the high beam indicator light on the dash.  when i operated the signal stalk and dip flash, i can hear clicking of a relay.  Either i knocked a wire off, lost a ground, or something more.   While changing the heater core tube on passenger side, it was very close to the fuse panel and wiring, so I may have knocked something out of whack!

4) the final gremlin - while engine warmed up to temperature, i noticed oil leaks.  One is at the rubber oil drain tube (from head to block) under the carbs above the fuel pump.   Looks like i might have to change that out.   it was a real dog doing that on my Elan, but actually it looks like i have better access on the Europa with the engine in backwards.

Another day, another project... :)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: jbcollier on Friday,June 09, 2017, 03:52:05 PM
1) Those heater valves are notorious for leaking, sticking and being difficult to adjust.  If you have a new one, just fit it.  The heater circuit needs to be bled.  Disconnect the two hoses at the engine and pour water/coolant in until it flows out the other.  There is an air bleed on the rad as well.  You also need to bring the engine up to temperature and get the thermostat open to clear all the air.

2) The rad fan switch is the ground side of the fan circuit.  Join the two together and it should work.  If not, troubleshoot and repair before runnnig the engine again.

3) Sounds like a bad ground under the dash.  This is also the ground for the everything up front including the rad fan.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Friday,June 09, 2017, 04:02:13 PM
Don't you just love teething problems!

The heater valve should be easy enough to test when you get it off the engine. There are better alternatives, too - modern inline valves - you might want to consider.

Presumably you have preserved the original wiring scheme even if you have replace some of the items (such as replaced the otter switch because you have an aluminum radiator). The temp switch completes the ground for the fan when the water reaches the appropriate temperature. That could have been tested before you installed it, but that's water under the bridge. When you test it in the car, it might not turn the fan on immediately upon reaching the temperature (at least that's what the switch I got for my aluminum radiator did to me).

Good luck with your oil drain! I have only heard it can be done with the head on, but I've never had to do it and since you've done it on your Elan, you are the expert on that!

Congratulations on your progress!  :beerchug:  It feels good to fix things and make the car better!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Friday,June 09, 2017, 05:11:21 PM
BDA - here is the write up I posted on Elan.net concerning replacing the tube in situ:

I developed an oil leak (pretty bad) at the rubber plastic drain tube between the head and crankcase there under the carbs and above the fuel pump. I thought perhaps the plastic tube hardened over the years and cracked, but much to my dismay the leakage was coming from the uppermost connection to the head. I removed the tube and found it intact, no split, holes, or hardening for that matter.
With great care, i was able to replace with a new one, and get this.... without removing the head. I read elsewhere that it can be done and yes, i was able to do it, rather easily i thought.
I accessed it by removing carbs, intake plenum, fuel pump and distributor cap/wires and misc stuff about. I trimmed the bottom connection a 1/4 inch. I used vice grips (narrow pointy nose kind) to squeeze tube in the center for a "flex point" to better bend it into place. I used a generous amount of RTV sealant, inserted bottom end in first and flexed the tube via vice grips while pushing top under the head overhang, and presto! It went into place. A couple twist turns to make sure it was seated both top and bottom and additional RTV sealant around the outside edges and I'm finished.

So it looks like i'll be repeating this feat on the Europa, but may not need to remove carbs/manifold since I have better access on this TwinCam as opposed to the one in the Elan Sprint.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Friday,June 09, 2017, 05:29:52 PM
You're the man, Ted!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Saturday,June 10, 2017, 01:08:28 AM
Your paying attention to all the right details Ted. With the level of work your doing it's time for a lift in your garage!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Saturday,June 10, 2017, 06:39:01 PM
Well I solved one of the problems.  I now have heat!   I think in the end it was an "air block".  I pulled the heater valve off and flushed it and the thermostat housing opening.  I flushed the line going to the heater core.  I found the heater valve working perfectly fine and re-assembled everything.  I started the car and it quickly came up to temperature and found the heater core lines getting hot as well.   I now have the heater core working.   Success!!!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Saturday,June 10, 2017, 06:41:22 PM
Just in time for Summer!


Seriously, good job!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Thursday,June 15, 2017, 09:21:36 AM
I drained off a quart of water and filled with a radiator/cooling system flush solution and ran the car for about a half hour to clean and wash the cooling system.   I'm actually going to leave it in there until near the end of the soft restoration process to thoroughly clean.   Sitting idling in the garage (well ventilated of course) the temp gauge crept up above 90, fan came on, temp dropped below 90.   This cycle continued the whole time, so i'm very pleased it runs cool while idling (without driving - stuck in traffic simulation) and that the cooling fan is doing its job well.   I remember my JPS #185 never had an overheating problem either.

Good news, since i grounded the ground wire, the radiator fan works fine, cycling on and off as needed.  The turn signals and high beam indicator issue also disappeared, so the ground was that issue.

So beside the big complete brake job coming up, the oil leaks must be addressed.   I'll need to replace the rubber oil drain tube (head to block) and the cam cover gasket and cam bungs sealed.  I also had oil coming out the oil cap itself, so that is not sealing properly.  I think that will address most of the oil leaks.   A degreasing of the engine is in order as well.

FUN, FUN!!!

Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: jbcollier on Thursday,June 15, 2017, 09:42:51 AM
Most rad flushing compounds are at least mildly acidic.  It is not a good idea to soak alloy engine parts for a long time in an acidic solution.  Use as directed and flush thoroughly afterwards with clean water.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Thursday,June 15, 2017, 04:10:51 PM
You make a good point.  I was only referring to their instructions where you can do the traditional quick 10-minute flush or they say you can leave it in for a couple days with various driving conditions for a more thorough cleaning.   So i guess i won't leave it in that long after all.   Thanks for the recommendation!:)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: brucelotus26r on Monday,June 19, 2017, 05:33:22 PM
I took my Europa out for a drive on Saturday and afterward looking at the radiator I noticed the fan switch was not all the way in and I could easily push it in or out. The switch and grommet are new and I don't see any thing to hold it in place ??
anybody have any ideas.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: jbcollier on Tuesday,June 20, 2017, 06:01:42 AM
I usually secure them with a long plastic zip-tie.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Stuleslie on Tuesday,June 20, 2017, 08:52:40 AM
Here is a picture of the Otter (fan) switch which is held in by a 'L' shaped bracket which is itself held by the hose clip. It must be manufactured as the one end under the hose clip is the same contour as the hose. Saying that a zip tye will probably suffice. I'm surprised it has not popped out under pressure before now.
Cheers
Stu
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: 4129R on Tuesday,June 20, 2017, 08:59:00 AM
I put a thin copper wire through the radiator matrix holes, and strapped it firmly to the radiator. I cannot see how the push fit ever lasted in place.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,June 20, 2017, 12:07:12 PM
MAJOR SET BACK.....
taking everyone's advice not to leave the acidic flush fluid remain in the system longer than necessary, i decided today that i would flush it out and fill with antifreeze.   Much to my chagrin, i found a curious puddle under the engine.   I feared and assumed it was the water pump.   I could not see weepage (combo seepage and weeping?) from above the crank pulley and wiped everything clean and dry.   The crank pulley kept dripping away.... I checked all over the back of the engine, looking at the freeze plugs, hose connections, everywhere......eventually with bright flashlight, while engine running, i could see the "weepage" coming from behind the water pump pulley, most likely the weep hole.    UGH!!!  !@#$%^&*

Not looking forward to it, but i suppose i should pull the engine.   While it is out, it will be easier to clean, paint, replace/install gaskets, etc.   I've never "pulled" the engine from a Europa.   Must the transaxle remain attached?   or is there enough room to disconnect and pull the engine away from transaxle toward the bulkhead to clear the clutch assembly??
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,June 20, 2017, 12:31:21 PM
I don't think you can take the motor out without also taking the tranny out. I would think that it would be easier to take the tranny out and then the motor.


If you can afford it, I would recommend getting a cassette water pump. Then, the next time you have to change the water pump (and hopefully you'll drive it enough to need to do it) you won't have to take the head off he motor to change it.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Tuesday,June 20, 2017, 04:12:36 PM
Ted, sorry to hear your bad news. I've taken two engines and transaxles out of two Europa's and both needed the transaxle taken out at the same time as the engine. Need to remove the axles first and then disconnect everything attached to the engine. Make sure you have an engine hoist that will go high enough.

I'm having my TC rebuilt to higher performance specs and I'm not putting a cartridge water pump in. Just rebuilding the water pump. Why you Ask? Well in a Europa you have to pull the engine anyway to change the water pump, so why would I spend all that money for a cartridge I can't change with the engine in place. Besides, from what I have read, the water pump should last at least 30,000 miles.

By the way, if your pulling the engine, might as well replace the clutch, pressure plate and throw out bearing.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: brucelotus26r on Tuesday,June 20, 2017, 04:23:29 PM
After working on mine I think it would not be to hard to drop the oil pan and pull the front cover out from underneath
with out pulling the engine.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Tuesday,June 20, 2017, 05:36:19 PM
How much will you charge Bruce to do the job for me?? :)

Glen, better think that through again....I think you can easily change the cartridge in situ from underneath.   Good point about clutch. :)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Tuesday,June 20, 2017, 06:37:15 PM
Well, I'm always willing to learn from others. I'll be interested in the process removing the front timing chain cover with the engine inplace. I'm sure it can be done, but just thinking about it already has my back in pain. The bigger issue (I think) is getting everything sealed properly putting everything back in.

I'll admit I'm known for "over doing it". I even pulled my Elan S4 engine just to replace the freeze plugs. Which buy the way you might want to check closely considering what you found in your water cooling system.

Here are some photos to help think this through.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Tuesday,June 20, 2017, 07:16:41 PM
I don't have a TC anymore so I could easily be ignorant of lots of things about them, but I am lead to understand that taking the front cover off the motor (or maybe it's putting it back on) requires taking the head off. Having just replaced the timing belt on my motor (and am not at all looking forward to the eventuality where I will have to adjust the valve lash - but that wouldn't be any different if I still had the TC), it seems to me that taking the head off is certainly not something to be done lightly and something to be avoided if possible.


Thirty thousand miles doesn't seem like a long life for a water pump. If I had to change it even every fifty thousand miles, I think I would appreciate the greater ease of using the cassette pump. It seems I've heard that they are not all created equal (that, too, is subject to my geezer memory) but I've never heard anything bad about the unit that Bean sells.


I also know that Certified Lotus is not alone in affirmatively eschewing the cassette pump so I am in no way making a judgement on that decision.


As I say, this is not something I have to concern myself with (I have bigger water pump fish to fry - I'll either have to rebuild my water pump or have another modified like the one I have when it's time to change mine). This is just a comment from the peanut gallery!  :)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: EuropaTC on Tuesday,June 20, 2017, 10:56:14 PM
After working on mine I think it would not be to hard to drop the oil pan and pull the front cover out from underneath
with out pulling the engine.
Yes, that's how I changed mine, it is tight but quite practical.

I was all set to remove the engine until the local Lotus specialist advised me not to do so but to leave it in place. Apparently  they always replaced Europa pumps without removing the engine. Once the head and sump area away then you'll be surprised how much access you actually have for the front cover, it only has to slide forwards a touch to clear the pump,etc. I think I slid the cover upwards into the engine bay rather than dropping it down but memory is hazy on that point.

Brian
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Roger on Wednesday,June 21, 2017, 12:06:11 AM
As designed the otter switch is a push fit only, no extra security. Sometimes it works OK, but many people have some other fastening.
MGBs share the design, and many have zip ties or w-h-y as extra precaution.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Grumblebuns on Thursday,June 22, 2017, 07:41:08 AM
After working on mine I think it would not be to hard to drop the oil pan and pull the front cover out from underneath
with out pulling the engine.
Yes, that's how I changed mine, it is tight but quite practical.

I was all set to remove the engine until the local Lotus specialist advised me not to do so but to leave it in place. Apparently  they always replaced Europa pumps without removing the engine. Once the head and sump area away then you'll be surprised how much access you actually have for the front cover, it only has to slide forwards a touch to clear the pump,etc. I think I slid the cover upwards into the engine bay rather than dropping it down but memory is hazy on that point.

Brian

For me the biggest worry with installing the front cover is being careful not to dislodge the water pump assembly while laying on your back under the car (having a lift might make the job easier). If you work carefully, apparently it can be done per Brian's experience. I for one will be going with a Dave Bean cassette water pump when the  replacement motor goes into my TCS

Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: EuropaTC on Thursday,June 22, 2017, 08:57:27 AM
For me the biggest worry with installing the front cover is being careful not to dislodge the water pump assembly while laying on your back under the car (having a lift might make the job easier). If you work carefully, apparently it can be done per Brian's experience. I for one will be going with a Dave Bean cassette water pump when the  replacement motor goes into my TCS
I can almost certainly guarantee that I wasn't on my back under the car, no garage pit in those days and a tendency towards laziness...     :)

Once the luggage tray, head, carbs and exhaust system are out of the way you can sit on the block and look down on the front cover.  But I still can't recall for certain if it came out upwards or downwards, but I have remembered that it was the seal that had failed, not the pump impeller or bearing, both of which were fine.   Whereas on the Elan's pump which I replaced in 2010,  it was the bearing that had collapsed and making rusty noises. But it had been there for around 30 years, so I didn't complain too much !
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Monday,July 17, 2017, 02:44:43 PM
Just an update.....there is no update!   I'm been either very lazy (on these hot, humid lazy days of summer) or not very motivated.   I remember last year pushing hard to get my Elan Sprint done in time for LOG36.  There was a reason to get it done, but here, i've got no deadlines, so it's been sitting patiently at the back of the garage waiting for me to get back to work!
A note of optimism, the water pump leak has slowed or stopped altogether.   Perhaps flushing the system with the acid-wash caused the water pump seal to leak?  Now that antifreeze is in the system, it seems not to be an issue.   Time will tell.

The brake system as a whole is a monumental task, however if i break it down into sections, i should just chip away at each task, and i would have been done long time ago.    Need to rebuild 1) master cylinder, 2) front calipers, 3) rear wheel cylinders, 4) brake boosters, then 5) bleed system and hope for the best!

After that, it's just claybar buff and polish.    Oh, and tidying up the engine bay, degreasing, replacing cam cover gasket, block oil drain tube, etc.

Gee, i'm awfully comfortable sitting in my easy chair watching TV right now.... :headbanger:
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Tuesday,July 18, 2017, 05:20:44 AM
I'm with you Ted. It takes a major event to get motivated to finish the car. And the hot and humid weather we have been experiencing in the North East isn't helping........

Plus you have a couple of cars that always need tending to, so it's easy to get distracted!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Thursday,September 21, 2017, 04:13:39 PM
Well after a less than productive hot summer (and now an "Indian summer" is upon us), I went ahead and had the car exterior detailed.  It involved a compound/buffing/waxing job.  It was done by my Lotus buddy Leo of "Professional Obsessive Car Detailing" out of South Plainfield, NJ.   Here's a couple shots.   If this isn't motivation to finish the soft restoration efforts, I don't know what is! :)
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Certified Lotus on Saturday,September 23, 2017, 03:50:20 AM
Looks great Ted! Lee does spectacular work :trophy:
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Grumblebuns on Saturday,September 23, 2017, 06:36:31 AM
Damn, it looks real good, always amazed at what a professional job looks like.
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: BDA on Saturday,September 23, 2017, 06:38:24 AM
There is nothing prettier than a shiny black car! She really looks beautiful!  :beerchug:
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Lou Drozdowski on Saturday,September 23, 2017, 11:17:53 AM
Ted, it's amazing what a little lipstick and nail polish will do for an old gal...!!! She looks ready for a date!
 
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Wednesday,December 26, 2018, 09:45:11 AM
FINAL UPDATE:
I sold the car earlier this year.  I forgot to officially close this thread with the news.
I never got to finish the hydraulics (brakes), so never actually road driven the car.
It went to a buyer in Florida.   Not sure if he is a member of this forum or not.   Sounded like a life-long dream of his to have a JPS, so I felt certain the car is in good hands and going to be completely restored to roadworthy condition once again.   This car deserved to be finished and driven.
Thanks for following.   onto the next Lotus project!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: Lou Drozdowski on Sunday,December 30, 2018, 05:11:06 AM
Ted, Sorry to hear # 059 has moved on...

Remembering your # 185 at Log 30, Now go and find another!
Title: Re: "soft" Restoration of 2933R (JPS#059)
Post by: tedtaylor on Sunday,December 30, 2018, 03:40:54 PM
is that a challenge Lou?    I just might take you up on that! :) ;)
I was just counting the other day.   I've had 40 Lotus cars over the years!   That's a lot of Lotus.    I just can't get enough...