Author Topic: My S2 project is now a driver!  (Read 951 times)

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Offline jbcollier

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Re: My S2 project is now a driver!
« Reply #15 on: Wednesday,June 14, 2017, 03:22:15 PM »
Very cool!

Offline Certified Lotus

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Re: My S2 project is now a driver!
« Reply #16 on: Wednesday,June 14, 2017, 06:24:33 PM »
Any interest in making me a pair of rear deck lid pins for my car?  Nice work!
« Last Edit: Thursday,June 15, 2017, 03:17:38 AM by Certified Lotus »

Offline 3929R

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Re: My S2 project is now a driver!
« Reply #17 on: Monday,June 19, 2017, 04:03:25 PM »
Worth the wait, I'd say! I can't wait to see it up close!
Mark
Salt Lake City, Utah, USA

Offline Keith A

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Re: My S2 project is now a driver!
« Reply #18 on: Tuesday,June 20, 2017, 04:34:08 PM »
Excellent work! Many many hours but well worth the time and effort, well done!

Offline Lotus7

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Re: My S2 project is now a driver!
« Reply #19 on: Sunday,June 25, 2017, 03:44:15 PM »
I’ve received a couple of questions about the Wilwood brakes I used at the rear of my S2. Here a few photos of my solution to adding disk brakes and some thoughts about why I did what I did.

My first requirement was that my solution should use the existing brake lines and hand brakes cables. In searching for rotors I discovered that the offset of the 2009 Ford Focus rotors would allow me to have a simple brake mounting plate. No offsets, not angles and no welding required. However, since the Ford wheel bolt pattern is 4x4.25” I had to drill four new bolt holes on my chosen 4x100 wheel stud pattern.

The mounting plate is somewhat heavier then optimal, but just fine for my proof of concept installation. It’s just a ½” thick 6061 aluminum plate cut to shape and then an ~1/8” relief was cut into the plate where it mounts to the trailing arm to center the calipers over the 0.35” thick disks. The caliper mounting holes were located per the drawings for the Wilwood caliper from their site. I choose to use their two piston Dynalite Pro caliper as the brake calculations seems to indicate that even with four small pistons per caliper it would provide excessive braking at the rear. This caliper did require a different fitting on the brake line vs the stock Europa drum brakes.

The parking brake is also a Wilwood unit. After I made my first mockup, I discovered that there was no easy way to remove the disk with the parking brake caliper in position. I added mounting ears to the ½” mounting plate to locate the parking brake. I also built a small, metal plate that is located by the Dynalite caliper mounting bolts. To this little plate I added a thicker piece to locate and secure the parking brake cable.

Of course mounting the Dynalite calipers at the top requires that the calipers be removed and held vertical when bleeding the brakes. At some point in the future I’ll likely build another set of mounting plates with the Dynalite calipers mounting vertically at the rear.

You can also see in the photos the non-stock axles I’m using. Originally I had the hubs machined to match the stock Europa rims and back plates for the stock drum brakes. However, with the new Ford Focus rotors I made a sleeve that I pressed onto the hub that located the center of the rotors as well as the center of the VTO Classic-8 wheels that I am using.

« Last Edit: Sunday,June 25, 2017, 07:44:43 PM by Lotus7 »

Offline BDA

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Re: My S2 project is now a driver!
« Reply #20 on: Sunday,June 25, 2017, 04:35:53 PM »
Very nice!

Offline Bainford

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Re: My S2 project is now a driver!
« Reply #21 on: Monday,June 26, 2017, 08:34:12 AM »
Yes, agreed. Nice work!
The Twin Cam plays the symphony whilst my right foot conducts the orchestra. At 3800 rpm the Mad Pipe Organ joins in.

Trevor

Offline 3929R

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Re: My S2 project is now a driver!
« Reply #22 on: Wednesday,July 05, 2017, 02:03:12 PM »
It's even more stunning up close and personal.
Mark
Salt Lake City, Utah, USA

Offline Certified Lotus

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Re: My S2 project is now a driver!
« Reply #23 on: Wednesday,July 05, 2017, 03:10:51 PM »
Very nicely done! You should be very proud!

Offline lotusfanatic

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Re: My S2 project is now a driver!
« Reply #24 on: Wednesday,July 05, 2017, 10:47:59 PM »
truly beautiful!

(that shade of gold/yellow suits it perfectly!)

Mark

Offline TCS4605R

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Re: My S2 project is now a driver!
« Reply #25 on: Thursday,July 06, 2017, 02:44:26 PM »
Lotus7 - did you use the stock Lotus alloy wheels?  If not, what wheel size, width and offset did you use.

Tom
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Offline Chuck Nukem

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Re: My S2 project is now a driver!
« Reply #26 on: Friday,July 07, 2017, 06:02:48 AM »
It looks unbelievable! That is absolutely the look I am going for on the s1. How did you do the rear fender flares? Do you have any pics of the process?

Offline Lotus7

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Re: My S2 project is now a driver!
« Reply #27 on: Sunday,August 06, 2017, 12:27:24 PM »
It looks unbelievable! That is absolutely the look I am going for on the s1. How did you do the rear fender flares? Do you have any pics of the process?

I do have some photos, I'll have to put something together. Basically we build one side using balsa wood. Once we had what we wanted and liked, we covered the balsa with some tape that the resin would not stick too and added some fiberglass to it. Then I removed the 'mold' and took it apart and reassemble it for the other side. It worked pretty good and gave us fended that match.

Offline Lotus7

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Re: My S2 project is now a driver!
« Reply #28 on: Sunday,August 06, 2017, 12:28:09 PM »
Lotus7 - did you use the stock Lotus alloy wheels?  If not, what wheel size, width and offset did you use.

Tom
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No, the rims are VTO's Classic 8 Wheels. Great people to deal with. I used the 15" rims front and rear. +24ET on the front and 0ET on the rear.
http://www.vtowheels.com/Europa_c_67.html

Offline Lotus7

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Re: My S2 project is now a driver!
« Reply #29 on: Sunday,August 06, 2017, 12:34:01 PM »
For those who like to look under the skin, hear are a couple of pics of the engine bay.

In the first pic you can see the new aluminum fuel tank.

In the second pic at the front just peeking out from under the headers you can see the AC compressor that is not yet fully plumbed into the system.

In the last photo you can see my custom setup for Suzuki 750 throttle bodies.