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Lotus Europa Forums => Garage => Topic started by: dakazman on Monday,May 22, 2017, 06:32:32 AM

Title: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,May 22, 2017, 06:32:32 AM
After years of sitting in my garage and working on it from time to time, first part going back on.
I sorted thru bags of parts , engine 821-30( needs liners ,need some help locating ) suspension,
Interior, body etc.. a lot of parts here .
Lol just found out last time I posted on yahoo was back in 2007...time flies.
Posted pictures on yahoo / 0453r reassembly/ dakazman

First part - steering rack.

This will be my log.
Dakazman
Dave Kaczmarek
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,May 22, 2017, 06:19:04 PM
Since I didn't see your first post,  :Welcome:  Dave!


I'm looking forward to seeing your progress. Working on the rack is pretty straight forward. The manual says that when you install the tie rods, they should take seven or so pounds to move - I'm not sure of the wording but I think you get the idea. They aren't kidding. I thought if they were tight enough to be snug but free swinging, it would be ok. I was wrong. I rebuilt the rack again and just guessed at how tight they were - envisioning the force to lift a gallon of water - and it worked fine, but a spring scale is the preferred method of testing it.


Good luck!
Title: Re: 1970 s2 0453R Reassembly
Post by: Bainford on Tuesday,May 23, 2017, 10:26:35 AM
 :Welcome: Welcome to the forum, Dave. Looking forward to seeing your project come alive. Cheers.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,June 02, 2017, 01:26:02 PM
While the parts were ready to hang, bolts needed replacement so off to buy some stainless steel
ones from lowes, well one sheared off with only being snugged up.
I see they were made in China. 😭. So off to a hardware store to find some American grade 5 bolts.

   I also used some anti seize on the leg thru mounts  since that is where a lot of corrosion was.
The bolts are 3 3/8 x 1/4 28tpi . Some minor hiccup was setting the angle of the steering column , which was not in the maintenance manual, just the 11/16 sparring.
Well pictures to come when I get a chance to resize them in a windows computer.
Tried to resize in photoshop express on an apple 6 plus, but no help wouldn't load .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: jbcollier on Friday,June 02, 2017, 04:08:24 PM
Yup, hardware store SS bolts are crap: cosmetic use only.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,June 06, 2017, 12:15:34 PM
OK posting some Pics>>>
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Tuesday,June 06, 2017, 12:20:35 PM
Pretty! I especially like the steering rack! Too bad you won't be able to see it when the car's put back together.
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Tuesday,June 06, 2017, 02:28:59 PM
Do I see a can of never seize ? If so, you are doing it right!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,June 06, 2017, 05:02:23 PM
Also hung the motor mounts , some brake lines, starting on trailing arms.
Maybe inner shifter linkage next. Object to clear off rack .

  I need to start ordering parts next ,the racing bushing kit from rd.
More pics to come ,
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: 46+1 on Tuesday,June 06, 2017, 10:54:13 PM
It's great you're working on her, I haven't touched either of mine for 8 years, been busy with lots of projects and getting old.  I do have spare parts, been collecting since 1974.
Whit
TC 2098R & S1 0478
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Wednesday,June 07, 2017, 05:26:12 AM
 :Welcome:  Whit! Hopefully one of your projects isn't getting old!  :)
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,June 07, 2017, 01:24:37 PM
 Getting old here also...black is what I'm going for , almost finished my el Camino.
Looks like finding a donor car for an 821-30 engine will be rough. Selling my Mazda 13 b engine on eBay now complete with eec and complete harness. Air box ,dash, oil cooler,ac unit,etc. I was going to go with a Kennedy hookup but changed my mind. Probably because of the swap to a dual turbo setup.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,June 08, 2017, 04:54:36 AM
Do I see a can of never seize ? If so, you are doing it right!
Certified lotus, yes it is...good eyes.
Lived in that area for many year,does Watchung sound familiar?
Great driving roads up there.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,June 08, 2017, 07:19:43 AM
Quote
Hopefully one of your projects isn't getting old!


Who's the dope who said that? Everybody knows your first project is to keep getting older!


Oh, that was me! Oops!


Don't be a stranger, Whit, and hopefully you'll be young enough to enjoy your Europas for a long time!
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Monday,June 12, 2017, 03:04:46 AM
Do I see a can of never seize ? If so, you are doing it right!
Certified lotus, yes it is...good eyes.
Lived in that area for many year,does Watchung sound familiar?
Great driving roads up there.
Dakazman

Ahhh, you know the area. Yes great driving roads right out of my driveway. A friend of mine and I went driving in our Elan's yesterday and he said the same thing.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,June 12, 2017, 06:17:14 AM
Going back to 1970 there was a lotus Europa dealership on Rt 22 in Scotch Plains, N.J.
That is where I saw my first time, purchased my basket case in 1985. Disassembled and striped,
Repaired all the spiderwebs in glass some time ago but it got pushed to the back burner.
Well more pics to come ,
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: cwtech on Monday,June 12, 2017, 01:25:46 PM
That was Tom's Pit Stop in Scotch Plains, where I bought my TC in 1974.

I grew up (?) in Stirling, and went to WHRHS.
Title: Re: 1970 s2 0453R Reassembly
Post by: BrianC on Tuesday,June 13, 2017, 05:28:45 PM
Tom's Pit Stop is where I saw my first Europa. I think I was 11 or 12 at the time. I grew up in Plainfield and would ride my bike to Tom's. I've always wanted a Europa ever since. Finally bought one this year.
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Tuesday,June 13, 2017, 07:29:23 PM
I also wanted a Europa since I was a kid. Was looking seriously in 2005 when the local Lotus dealer (Sports and Specialist Cars) convinced me to buy a new Elise instead. Went thru that phase of "new" Lotus' and finally decided I still wanted a Europa. So here I am in the midst of my frame off rebuild.

My friend Ted had both an Elise and a JPS Europa (lucky guy)

Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,June 16, 2017, 07:22:21 AM
Hey certified. Great pictures of Teds Bookends.

Cwtech and Brian , right Toms pit stop...he would have several on the front lawn.
Small world.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,June 16, 2017, 08:25:16 AM
At first, I thought the Elise was way to garish for me, but I've warmed up to it. I got a chance to sit in one a while back. I expected it to be a bit difficult, but I didn't expect it to be nearly impossible. It would have been much easier with the top off, but the hard top was installed. It probably took a couple of minutes to get in. Once in, it was ok. Getting out wasn't trivial either. They're interesting cars but there's no danger of my getting one. On the other hand, an Elan... (by why not a Miata?)
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,June 25, 2017, 03:09:34 PM
busy week here,
progress report. pictures first heater /defrost box rebuild
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,June 25, 2017, 03:13:45 PM
ok some radius arm stuff also cleaned...but bushing for wishbones cam in and 2 engines from California coming
 an 821-30 wedge and an 843 hemi.
dakazman   
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,June 25, 2017, 03:23:15 PM
also dug out the box with my interior parts ...
talk to you all next week>>>
busy, 
dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Sunday,June 25, 2017, 04:34:13 PM
Great progress! If you decide to get a new dash, I would recommend Prestige AutoWood (http://www.prestigeautowood.com/). I don't have any interest in his business, but he does great work!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,July 07, 2017, 03:40:01 PM
 Hey guys Great week , I received two motors from a great guy from California
A hemi and a wedge .  Trying to find a good machinists ... had a simple job so I thought was to cut the rear drums and the front rotors but was turned away because there is no written Specs on this in the maintenance manual. Frustrating....
Title: Re: 1970 s2 0453R Reassembly
Post by: jbcollier on Friday,July 07, 2017, 07:02:38 PM
Rotor are cheap, stupid cheap.  Just buy new ones.  Same as a Spitfire.

Drums are the same as a GT6. Early GT6 for the S1/2 and TC (1.25"), late GT6 for the TCS (1.5").  A little harder to find and they are not balanced when you do.  Trust me, get them balanced.

If the drum is not scored, you can just sand them.  The problem with turning the drums is that when you get the big cuts (no more than 0.060"), the shoes no longer fit well.  In the old days, we would arc the shoes to suit but there are not many shops so equipped these days.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,July 09, 2017, 08:12:17 AM
Thanks ordered front rotors , may go with the upgrade and put discs on back .
I'll check back with progress and pics soon
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,August 02, 2017, 03:40:42 PM
Still working on numerous parts, but I received a 843 hemi crossflow engine and need some help  ordering parts  and identifying engine. I see mecaparts has some parts I believe but find it hard to navigate the site. Any help would be appreciated
Thank
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: jbcollier on Wednesday,August 02, 2017, 04:15:47 PM
These two pdfs go into what fits where with the Renault crossflow engines:

http://www.lotus-europa.com/manuals/s1misc/PFEngineering.pdf

http://www.lotus-europa.com/manuals/s1misc/s1hemi.pdf

843s use the same bearings, etc but use different sleeves with an o-ring seal.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,August 02, 2017, 05:36:25 PM
Thanks , here's some more pics
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,August 02, 2017, 05:49:03 PM
I see it is an 843  but how do we determine the - #...
13/15/17 gordini is labeled , gordini.?
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: jbcollier on Wednesday,August 02, 2017, 08:50:09 PM
Only early 807 engines had the high compression, large valves and large ports that people associate with a "Gordini" engine -- BTW, Gordini actually had nothing to do with the 8-- series engines.  An 843 can be brought up to "Gordini" spec by fitting larger valves, porting the head, fitting h-c pistons, etc.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,August 03, 2017, 05:43:23 AM
My 821-30 engines also coming along and getting it ready for machinist, but I need to order gasket for liners , paper type. The shop will set the liners and send out cranks and cams. yes 2 each of the 821's.
Heads now completely torn down and accessing conditions. The original engine block will be reinstalled with parts from both. Only after rebuild will I consider undertaking the 843 , but will start looking for the parts.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,August 03, 2017, 12:37:12 PM
Just finished the headlight assemblies and decorated garage. Lol
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,August 03, 2017, 02:45:57 PM
Other items in work...paint on the corvette and el Camino.
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,August 03, 2017, 04:47:02 PM
That will keep you off the streets!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,August 05, 2017, 09:43:42 AM
Just received an original air cleaner and was wondering if anyone could tell me what an original cutout looks like. Or PDF an drawing of a tracing😁
Thanks in advance
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,August 18, 2017, 04:48:34 AM
 Finished the lower plate in the air cleaner and readied new plate for welding back in.

On a separate note purchased a rear luggage compartment found on eBay after 25 years
It needed a few repairs but coming along. Other items completed were radiator fan assembly and demister fan
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,October 02, 2017, 06:18:46 PM
As stated earlier I finally found a tray for aft compartment, here some pics of
The progress of filling all the holes and cracks. Primed today and I will post those soon.

Wheel wells and tunnel pics and progress. Wheel well undercoating was terrible to remove.
Newer Honda wheel well material will be attached to keep road noise down.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,October 02, 2017, 06:24:48 PM
Body in prime.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,October 02, 2017, 06:59:46 PM
Also front turn indicators need to be redone because they were glassed with fabric and they are
Lopsided. So I made the inserts and will install correctly this week.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,October 02, 2017, 07:52:14 PM
Looks like a lot of work ahead of you! Thanks for the pictures! Keep them coming!
Title: Re: 1970 s2 0453R Reassembly
Post by: andy harwood on Monday,October 02, 2017, 08:20:08 PM
Wow! You've really been on a roll. Looking great!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,October 05, 2017, 04:08:52 PM
 New turn signal holders. Rought install.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: jbcollier on Thursday,October 05, 2017, 07:20:26 PM
I wish they had put them there originally.
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Friday,October 06, 2017, 04:42:13 AM
Great work! You have nice momentum and that is what keeps a project moving.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 06, 2017, 06:40:41 AM
My momentum is because of the help and information I get from all the talented people here.
All glass work except interior dash and firewall done. My firewall will be removable from interior so that fuel cells can be accessed easier. Lol maybe even smuggler’s compartments .

The longer ,cleaner , lines from front view are undisputable😀, however I believe it is weaker, so no sitting please.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,October 17, 2017, 01:03:30 PM
  :BEER3:
I just primed my baby I couldn’t stand the engine compartment and spare tire are so I prepared that for paint also 80 hours later this is what it looks like.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,October 17, 2017, 01:08:30 PM
Missed one😀
Title: Re: 1970 s2 0453R Reassembly
Post by: Bodzer on Wednesday,October 18, 2017, 03:26:11 AM
Oooh, that looks nice! Well done! Can you come over and prep mine?
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Wednesday,October 18, 2017, 05:26:30 AM
She's looking great! Do I remember correctly that you'll be running a Renault motor? What size tires will you be running?
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,October 18, 2017, 02:21:07 PM
I saw a thread on tire size and they are on my list to buy.
I have panasport 13x8 for rear and 13x7 rims for front.
Hopefully soon I’ll get to rolling frame around . Waiting for rear bearings from
Kelvedon lotus which is next on my buy list.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,October 19, 2017, 03:00:29 AM
 BDA, yes,Renault original stock 821-30 engine.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 20, 2017, 03:05:46 PM
Blocking it out is going nicely, these pictures are the wet look.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,October 20, 2017, 04:14:22 PM
Very nice! Don't forget to reinforce the upper corners of the windscreen area.
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Friday,October 20, 2017, 04:39:02 PM
I am in admiration of people who do their own body work.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 20, 2017, 06:25:33 PM
 Thanks Bda and certified. I read about those reinforcements and thought it sounded like a good idea.
I will respray primer and add contrast agent to paint before sanding again.

    Then getting back to glassing dash support back in and building firewall.
Thanks certified for the pictures.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,October 25, 2017, 04:24:06 AM
Dry guide coat applied . Blocking shows some low spots but overall
Coming along nicely. The guide coat is great stuff and takes the
Guess work out and poor eye sight . Lol.  Just good and bad.
Looks like 1 or two more coats of primer.
The weather finally in mid 70s and dry ,perfect for painting.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,October 26, 2017, 06:22:57 PM
Dash support back in , rear and rearluggage bin prepped .
Washed again and ready for more primer tomorrow

I need some ideas for firewalls preferably removable.
Material and location? Also is my favorite glass mixing tray
Lol it cleans up easy after drying just bend and it’s clean.

Dakazman

Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,October 26, 2017, 06:53:54 PM
Great progress, Dakazman!

It seems the usual material used for new firewalls is marine grade plywood covered in fiberglass. I'm not aware of anybody making a removable firewall but some people make a door for access to the front of the engine.
Title: Re: 1970 s2 0453R Reassembly
Post by: 4129R on Thursday,October 26, 2017, 10:07:32 PM
Great progress, Dakazman!

It seems the usual material used for new firewalls is marine grade plywood covered in fiberglass. I'm not aware of anybody making a removable firewall but some people make a door for access to the front of the engine.

I used 12mm ply, covered with fibreglass when replacing the soaked thick cardboard originally used.

Richard at Banks said he just glass fibre covers any bad original firewall. That is what I plan to do to 4129R this weekend.

As it is a "firewall", any removable panel should not compromise the passage of flame/smoke. Difficult to seal the perimeter of the removable bit. 
Title: Re: 1970 s2 0453R Reassembly
Post by: Bodzer on Thursday,October 26, 2017, 11:55:10 PM
Well done again!

How about Aerogel insulation sheets? My only concern is that Aerogel itself is hygroscopic but I think when it’s impregnated into sheets it isn’t much of a problem. Different types sheeting are available depending on the level of thermal performance required.

Title: Re: 1970 s2 0453R Reassembly
Post by: Runningwild on Friday,October 27, 2017, 04:49:10 AM
I sandwiched the original firewall with .030 aluminum then aluminum honeycomb heat shield. 
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,October 27, 2017, 05:21:32 AM
I sandwiched the original firewall with .030 aluminum then aluminum honeycomb heat shield.


Now that is a FIREwall! :)
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Friday,October 27, 2017, 06:04:08 AM
I sandwiched the original firewall with .030 aluminum then aluminum honeycomb heat shield.

Not exactly “adding lightness”  :FUNNY:
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 27, 2017, 06:14:26 AM
I sandwiched the original firewall with .030 aluminum then aluminum honeycomb heat shield.

That is a masterpiece 😀👍

That’s where I was leaning, aluminum and aircraft mechanics get along nicely. I only have a beef with getting to the fuel tank/ tanks. When I purchased the car the fuel tank was cut out of the bottom of the car. I am not going thru that repair again so that’s why I will split your design into 3 pieces.
Aluminum t- channel uprights and glass angle  around perimeter.

PS taking the day off . 😄 Became a Grandfather for the forth time last night
To a baby girl , Madison.

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,October 27, 2017, 06:51:52 AM
Congratulations on your granddaughter, dakazman!
Title: Re: 1970 s2 0453R Reassembly
Post by: lotusfanatic on Friday,October 27, 2017, 06:52:50 AM
Dakazman,

Congratulations to you and your family!

Mark
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 27, 2017, 07:25:02 AM
Thank you 
Baby and first time mommy healthy and doing fine😀.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Runningwild on Friday,October 27, 2017, 04:28:47 PM
The alum and the heat shield only added around 5 pounds. Very light weight stuff   
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,October 27, 2017, 06:37:31 PM
I like the look and layout of he heat shield material. Is the aluminum sheet on the engine side or under the heat shield? I’m assuming it’s on the engine side , hence the word sandwich.

The original “firewall” straw type sound board for material left much to be desired at least in my
Vechicle. Your addition is the closest to a true firewall.

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Saturday,October 28, 2017, 03:40:18 AM
A fiberglass car will burn so quickly it doesn’t really matter what you add to the “firewall”. If you detect a fire in your car, get out! And fast.

How do I know? I’ve seen two Lotus Exige’s burn at the track. Even a complete fire suppression system in one didn’t stop it from burning.

All I’m adding to my “firewall” is a sheet of heat insulation on the engine side as I took out the old horse hair mat. It will be lighter.

Congrats on being a grandfather (again)!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,October 28, 2017, 04:44:14 AM
Thanks certified,

I held back on stating that. Its not that I believe it is a firewall but just a barrier for
Carbon monoxide, dirt , dust, water , fire , sound.   
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,October 30, 2017, 05:39:44 PM
After reading a pfd  by Dave on firewall I have a new approach.
See pic 1 , view from engine compartment. Glass flanges going on.

   Secondly, final black going on see bonnet.  Bring up the level of engine compartment and front luggage compartment and spare tire area.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,October 30, 2017, 07:38:07 PM
Thanks for the pictures, dakazman! That black looks great and it sounds like you have some interesting ideas about your firewall. I'm looking forward to pictures of it when you're done!
Title: Re: 1970 s2 0453R Reassembly
Post by: buzzer on Tuesday,October 31, 2017, 08:27:23 AM
I used a lightweight 5mm thick honeycombe fibreglassed on both sides bonded into the body then a thin sheet of aluminium alloy riveted on the engine side
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,October 31, 2017, 05:15:50 PM
Thanks buzzer and bad.
Primed the body / front and back luggage trays, the front was terrible, so many small divers in glass
Engine compartment looking good  the black is 9900 base black , any other black looks light in it .
The bad part is it needs to be cleared 30 minutes after spraying . Cleanup on two guns afterward, is well worth it . The cardboard cutouts were for my perspective of a clean compartment. The firewall  will still be in its original place. The addition of two removable side engine panels will hide a lot of  unfinished areas. I placed the fuel tank in and took measurements of the panel behind seat .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 02, 2017, 05:19:57 PM
    First coat of paint and clear on luggage compartment.

    Forward compartment ,engine compartment and spare tire area coming along ..
I can’t stop .. helppppppp.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 02, 2017, 06:00:26 PM
Progress is addictive! It feels good! Keep going!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,November 08, 2017, 04:25:38 PM
Ok firewall supports installed and the panels coming along.

Then on the lighter side , are there drain holes in the forward
Luggage compartment and if not should I add two?

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Wednesday,November 08, 2017, 07:19:14 PM
The front luggage compartment is supposed to be dry so you can put luggage in there!
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Wednesday,November 08, 2017, 09:53:42 PM
Then on the lighter side , are there drain holes in the forward
Luggage compartment and if not should I add two?

to follow on from BDA, not only will the front compartment probably be the driest part on your Lotus (don't laugh, "Dry" and "Lotus" can work together  :)  )  but it's also supposed to be sealed around the edges to act as a plenum chamber to pressurise the fresh air and heater vents into the car.  So in theory anything other than the blower inlet and cabin outlets would reduce the efficiency of the design (now you can laugh.... ;)  )

Brian
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 09, 2017, 04:06:53 AM
Thanks guys, I was just wondering how dry it stays. I saw the seals and gaskets in many pictures
But the monsoons we get here I thought it might be a good idea to check with others who actually drive their car. I also found I forgot to add the drain under the headlight assemblies .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Thursday,November 09, 2017, 09:37:12 AM
It stays dry because of the lip in the bodyshell around the edges. As long as you have a decent gasket in the compartment lock you will be fine.

But talking of leaks from that end of the car I did have an odd one where the lock fits into the bodyshell just below the windscreen. There should be a little rubber moulding behind the metal plate/slot into the bulkhead which seals the interior and mine had worn away over the years. Water drips down the bodywork, lands on the locking plate from the lock mechanism and then wanders inside your car - a Lotus is always interesting.....
Title: Re: 1970 s2 0453R Reassembly
Post by: 4129R on Thursday,November 09, 2017, 10:04:22 AM


But talking of leaks from that end of the car I did have an odd one where the lock fits into the bodyshell just below the windscreen. There should be a little rubber moulding behind the metal plate/slot into the bulkhead which seals the interior and mine had worn away over the years. Water drips down the bodywork, lands on the locking plate from the lock mechanism and then wanders inside your car - a Lotus is always interesting.....

I always wondered why that black rubber was there. Mystery explained.

Another mystery is an aluminium plate on the edge of the bonnet (hood) opening just by the radiator fan. It was only fitted to 1974 models.
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 09, 2017, 10:10:42 AM
That was to keep water from draining from the rain gutter on to the fan motor. The US club, Lotus Ltd., used to sell them back in the day. I suppose they or something similar was sold in the UK also.
Title: Re: 1970 s2 0453R Reassembly
Post by: 4129R on Thursday,November 09, 2017, 10:30:58 AM
That was to keep water from draining from the rain gutter on to the fan motor. The US club, Lotus Ltd., used to sell them back in the day. I suppose they or something similar was sold in the UK also.

Thanks for the explanation.

All that extra weight. Add the weight of the water in the front by where the spare wheel has been taken out, and the power:weight ratio has been ruined.

All these extra things to stop water getting in the bonnet lock hole, or dripping on to the radiator fan, when the windscreen and the doors leak like a sieve.

Plus water get on the the cylinder head where the front two plugs are, and the casting between 2 & 3 is not drilled to drain to the rear, like it is open at the back behind #4 plug.
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 09, 2017, 10:51:21 AM
The car leaks pretty much everywhere. I've seen some put an aluminum cover over the valley between the two cams on the TC to keep the water out a little at least.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 09, 2017, 01:29:55 PM
 

Quote
The car leaks pretty much everywhere.
Lol that’s exactly what I’m looking for, a sore spot....someone
Drilled a hole in the little stiffener just above the drivers leg in the forward luggage bin , I repaired that. I would love to here more.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 09, 2017, 01:55:49 PM
In my own experience, both of my luggage compartments stay dry. My doors leak though. Some have theorized that the modern door seals are different enough from the original that that is a cause. I would also suspect that most of us (certainly myself included) have not rehung our doors as accurately as they were hung at the factory. When mine was new, there was a slight leak in the passenger door. Now it is "a bit more." It's all part of the fun of owning a vintage Lotus!

I have seen several cars when they were nearly new with stick-on foam rubber in the rain gutter of the bonnet or around the front luggage compartment so some have had a problem there.

The guy who installed my windshield would not guarantee that it would not leak. Thankfully, it doesn't and never has.

I would wait to see if and where you have any leaks. I would only use a drill for draining body work but would stick with seals to keep the water out of where you don't want it. Here's a catalog that might be useful (https://www.steelerubber.com/universal-parts).
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 09, 2017, 02:17:17 PM
 BDA,  I fully understand leaks ... I own a 79 corvette with glass t tops that have leaked since I purchased the car in 1998 I replaced all seals  and envelopes purchased a set of fiberglass tops
All leak when it rain 10 inches an hour . (Usually on my wife’s side) As I stated , I have never driven a Europa and do love all the input.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 09, 2017, 03:08:10 PM
Interesting that your 'vette leaks on your wife's side! I think you now have to make double sure that your wife's side of the Lotus doesn't leak!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,November 15, 2017, 06:48:22 PM
   Checking in , firewall ,sanding and painting moving along.
Center Firewall panel molded from ScotchWeld EC 3524 which is a fire retardant compound
that I will coat with black carbon fiber. The two remaining panels behind the seats will be done the same way. Attached is the data sheet of the compound. The “close out panels will be carbon fiber.
See the cardboard template.

    Body has been sanded down to 600 grit so to see any remaining defects,and I did find a hairline crack just below the sail area probably caused by someone leaning on it . I also made a newbie
mistake and used a grinder with a whip hose that I pulled and tore a nice gouge in the door jamb .
One last coat of primer should do it .

   Painting the black panels are awesome looking but that's just my opinion, but it'st nice to see a final product... almost.

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Wednesday,November 15, 2017, 07:05:28 PM
That's looking great! Is that stuff good for sound deadening? That would be an important consideration.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 16, 2017, 03:17:28 AM
 Yes it absorbs sound, weight of balsa and is completely waterproof . I will still put up a sound barrier and carpet as it originally had.   —-It is not easy to work with.—-

Dakazman

   
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,November 17, 2017, 04:36:16 PM
 Doors,aft luggage tray in black and moving along .other pieces and body in last coat of primer
And sanding to 800 for paint... super jet black g9900s. And cleared within 30 minutes.
That’s me in the paint😀
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Friday,November 17, 2017, 05:02:12 PM
Impressive work and momentum! I’m envious of your available time to get things done.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,November 17, 2017, 06:13:14 PM
Certified 
    I’ve been put out to pasture from my job because of a small disability.
I’m working with mostly only my right arm . I had a torn rotator cup  and needed anchors put in ,
Weight restrictions put on by doctor is why I have not been allowed to return to work. A technician
Must be able to lift 70 lbs  ...I can’t torque wheel bearings to 600 ft lbs  for sure..lol I have trouble with 6lbs on the left side. I remain optimistic and waiting for an offer with my company in another capacity. So I’m in my garage daily keeping busy.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,November 17, 2017, 06:25:19 PM
Sorry about your disability. It doesn't seem to have impeded your progress at all! That black is super deep! Very pretty! But are you ready for an unairconditioned black car in Florida during the summer?! Or are you planning on installing A/C?
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,November 18, 2017, 02:57:20 AM
 I drove a pickup for many years without air , I will have ac is this car and have read about the demands on the electrical system and accessories, and cost. I’m still a long way off for that system.
After paint the harness will go in, lights . Building up doors is another whole project that I see and from what I read I think I’ll go with the stainless door pins .

    I can’t decide weather to put the cooling tubes in frame or shifter linkage first it seems the tubes take up a lot of room transitioning in and the shifter rods might get in the way . On the other hand I need to buy the stainless tubes because of just the fact that the ones I have are almost 50 years old .
All these upgrades..... I’ll be done by next week. . lol
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Saturday,November 18, 2017, 04:04:18 AM
Dakazman, seems like the work your doing on your Europa is the best type of physical therapy one could experience. Plus your enjoying your rehabilitation  8)
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Saturday,November 18, 2017, 05:13:20 AM
What Certified said,

It sounds like you're going to have a super car when you're done!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,November 19, 2017, 04:14:08 PM
 
First coat on body...yeah 👍
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Sunday,November 19, 2017, 04:19:38 PM
Nice!
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Sunday,November 19, 2017, 05:27:56 PM
Impressive work without a paint booth!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,November 20, 2017, 03:16:21 PM
That’s the beauty of base coat / clear coat  base dries so quickly it just needs a tack cloth before clearing. After clear coat you sand 600 or higher. Repeat till satisfied on base . Then apply several clear coats , buff and sand till you can’lt lift anything...
Dakazman 
Title: Re: 1970 s2 0453R Reassembly
Post by: jtkerka on Thursday,November 23, 2017, 01:43:47 PM
  Dakazman: Beautiful job on your rebuild so far. I am jealous.  I have had a 1970 S2 ( 0063R ) for twenty years and am
just now getting ready to rebuild it. I have it stripped and the next job will be body removal. I will be reading your posts to
get tips and ideas on what needs doing. Keep up the good work and thanks for sharing with the group.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,November 23, 2017, 03:04:59 PM
 Jtkerka.
Welcome to the forum. Glad to see another s2 coming back from the grave. Lol .
I will keep you up to date . Remember to take a lot of pictures, it will help you document your progress and help putting it back together. Please introduce yourself to all and tell us more about your ride. 20 years sitting but I see some work accomplished. What type engine ...etc,etc.

  There is a lot of great info here and links to many more vendor sites .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,November 23, 2017, 05:27:10 PM
 :Welcome: , jtkerka!


Don't forget to ask any questions you might have. Several of us have been were you are now. And like dakazman said, we like pictures!!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,December 06, 2017, 03:07:20 PM
First piece semi completed  my 3 step method plus some 3000  glaze. Pictures are not wet just the finishing u
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Wednesday,December 06, 2017, 03:45:57 PM
That second picture pretty much says it all! Great work!  :beerchug:
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,December 08, 2017, 02:26:59 PM
Hers a door
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,December 08, 2017, 02:47:00 PM
That black paint is just miles deep! Very nicely done!  :beerchug:
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,December 08, 2017, 04:47:39 PM
That’s the corona base G9900 black . It’s the base for all dark colors the deepest black made.
When sanded out and using the 3 step 3 m process to finish it looks like a black mirror.
I used a foam cutting pad next will be a foam finishing pad.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Friday,December 08, 2017, 11:09:26 PM
It really is nice work. I know black can polish up well and that putting the work in will give great results, but yours is the best I've seen.  I would be very, very proud of a finish as good as that.

Brian
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Saturday,December 09, 2017, 03:15:30 AM
Amazing work Dakazman!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,December 09, 2017, 04:25:56 AM
Thanks guys I really appreciate your comments. I will keep posting pictures and today I should have the body ready to buff out. Hopefully I can get it put back together without scratching it ....
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,December 17, 2017, 06:34:30 PM
Body panels coming along , arm getting sore ... lol.
Keeping it short because after the last software update on my apple phone it reboots at will showing a full battery then next minute   0 charge 
Here’s some pics .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,December 19, 2017, 05:18:23 PM
Door at 5000 grit and buffed 😀. Now for the inner section
Dakazmang
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Tuesday,December 19, 2017, 06:19:06 PM
Spectacular!
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Tuesday,December 19, 2017, 07:36:52 PM
That car is going to blind people in the sunshine!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,December 22, 2017, 04:09:14 PM
 Hard to take a good picture of black paint 😳 most of car has no orange peel  and no swirl or scratches. I need to do edges and fed compartment and engine section.

Merry Christmas to all .

Enjoy the pics!
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,December 22, 2017, 04:23:51 PM
You painted your car without a booth?! Amazing!

Merry Christmas to you, too!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,December 22, 2017, 04:51:55 PM
Yes , No booth . Spray color , clear coat within 30 minutes , let dry approx 20-30 minutes bring outside to stop the smell . Work the next day sanding .  Painted my Vette  and my Camino and others the same way.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Friday,December 22, 2017, 11:15:25 PM
I do like the 'vette.  :)

Ok, I know I'm on the wrong side of the pond for these but I've loved the shape ever since my uncle sent over a book on the cars for a Christmas present when I was a  kid. It's big feature was the Mako Shark version and we had nothing like that over here at the time - that image is still fresh today !

Question - are you using a mechanical polisher or is it all hand polishing ? Whatever you're doing it's just stunning.....

Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,December 23, 2017, 04:38:45 AM
 All mechanical ,except for edges and tight areas. After painting wait the recommended time to cure . Then
Sand high spots out as you do with the primer but with 800 to 1000 initial cut. i use mostly all velcro pads and dics.

    Very important FREQUENTLY check the sanded area with a rubber squeegee pad . As the glossy areas disappear step up the sanding grit 1500,2000 buff with coumpound and redetermine if more sanding is required, . Meaning do you see any inperfections you are not happy with,now is wipingtime to keep sanding ...sometines going back to 1000 and bring it back up to 2000..then rebuff with a cutting pad at a slow to moderate speed. More on that later . Remember slow and wet wiping area as you make a pass with a orbital sander.

  Now if your happy with area time now to step it up ,attach a sanding pad  sponge pad on sander which i like to keep on sander as to protect the edges of a panel against burn through. 
  Attach a 3000 pad, 4000, and 5000 ,sand an area in slow passes for approximately 4 good passes each. 3m has a great product that is expensive 10.00 dollars each in the 3000 and 5000 but all you need is two for a complete car.
The velcro equivalent is .80 cents. Will post a pics on equipment mentioned
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,December 23, 2017, 06:01:22 AM
 Here are some tools.

Merry Christmas
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Sunday,December 24, 2017, 01:29:43 AM
Thanks for posting the pictures of your tools, it's an area that I know zero about but would like to learn more.

We're similar in our approaches to painting cars, although I try to get as good as possible a finish from the gun, invariably there are sections that need polishing. With my Elan I have a good finish with reflections almost as good as yours (red doesn't have the same effect though), but that's because it's a small car and quite curvy, so the paint flows well.  And with a small car it's easy to hand polish.  I do a similar process to yourself, I used up to 1200 to get it matt & then cutting compounds - G3 paste, a fine "T-cut" grade and finally polish.

With the Europa and the large flat areas I have always needed to polish and I must admit, I get tired doing it by hand. The car is ok but I put enough paint on that I know it could be better, hence the question on tools. I've been hesitant and wary of burning through the paint, but what you're doing has convinced me to look again.

I can see you have an air tool but is the one at the back electric ? I prefer electric as my compressor is only 9cfm (and noisy) which is probably borderline for pro tools, so if you have any advice on what I should look for I'd be obliged.

Brian
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Sunday,December 24, 2017, 05:46:01 AM
 The one above the 2000 grit is the only January  :BBQ:  electric tool. It is not god for small , tight areas however .
This was the most difficult car to spray the entire car without overspray. I thought I would just spray a section at a time but taping areas would be time consuming. So I took the best start to finish path.
Yes I agree to get a good flow to the finish coat and I can do that most of the time without running the paint.

Doing small areas with the Trizact pads by hand or by machine will protect against burning thru because of the sponge backing, and I also place the sponge backup pad in picture on sander Velcro pad to prevent sander from digging in when changing directions of the sanding.
There are numerous foam pads for cutting, polishing and finishing . McGuire’s has a great video on you tube where the polish out a car for 8 hours with 6 guys ,(boring), but we/ I can fast forward and get to see what the pros do.

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Sunday,December 24, 2017, 09:32:12 AM
does the use of foam pads prevent it digging in or overheating ?  Interesting if so, but as I said it's an entirely new game to me. I think I'll spend some time browsing youtube and see what's there.

Merry Christmas.....
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,December 25, 2017, 05:09:38 AM
Yes it does help in both. Slow and easy with light passes
Door jamb and sail panel polished.

Merry Christmas
Dave K
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,December 26, 2017, 04:55:27 AM
 No burn thru on door interior. Window section was sanded by hand.
I left a lot of defects in this area that I usually take out
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,December 26, 2017, 12:59:40 PM
Polished out and finished edges
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Tuesday,December 26, 2017, 05:00:23 PM
Outstanding! You're going to blind other drivers in the Florida summer sun!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,December 27, 2017, 04:40:23 PM
Thanks BDA,
I’ll try to drive it only at night. Anyway enjoy some more blinding pics.😁
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,December 29, 2017, 04:22:59 PM
I was a little bored today so I played with the aft luggage compartment. I may have overworked it a bit since it was blown off the hood of my El Camino and down driveway .I couldn’t run fast enough. I guess I’ll be practicing by blending skills . It is only on the bottom corner and bottom side and will paint when the weather warms up
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: surfguitar58 on Friday,December 29, 2017, 08:29:48 PM
You are definitely the paint guru of this forum dakazman, but now you're just showing off. ;) Don't most people put carpet in the bottom of their luggage tray?
 
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Friday,December 29, 2017, 08:44:00 PM
Your on a roll, keep up the great work!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,January 02, 2018, 04:14:57 PM
Cleaned up my attic and reunited some parts stored for years , windows ,door trim ,windshield wiper assembly and all the rubber seals . Cannot find any of my emblems  except for the forward lotus badge.
    It’s a 4 Month waiting line on my bumpers that I delivered for chroming . I need to add a few escutcheons from the wiper assembly .

Surf guitar 58 😀 I guess I was showing off a bit , the compartment I pictured on page 3 show the sad shape of the tray , and the tray has been a struggle to finish. After the shock of seeing it flying away also.  . Thank you for your comments  . I strive for perfection but find it better to finish and go back to an item. I have seen a lot of really beautiful examples that I might achieve that level .
Here are the blisters I repaired and waiting to paint and blend in.

Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: surfguitar58 on Tuesday,January 02, 2018, 08:28:17 PM
Amazing job, clearly I'm just jealous!  :trophy:
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,January 05, 2018, 08:02:30 PM
Finally got my iPhone to stop hesitating long enough to post these pics of the blisters.
Now just waiting for the temperature to hit 65+. I haven’t much luck blending the clearcoat in,
With the use of a blender agent but will post pics.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Friday,January 05, 2018, 08:31:08 PM
Bummer! Somehow I have confidence you'll turn that into another black mirror!
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Friday,January 05, 2018, 11:53:54 PM
Hi again, and apologies in advance for going off topic (but I'm still gonna ask  ;)  )

After seeing all this work you've convinced me to have a go with modern kit, so I've bought myself a dual action polisher, called a DAS6Pro over here, I don't know if you have the same things over there. It's got variable speeds and I've got a 5" & 3" backing plate with Hexlogic Heavy/Medium/Finish velcro pads - basically I've been trying to copy what you showed a page or so back.

The last polisher I had (several years ago) vibrated so much that I had aching wrists after a few minutes and the polishing mops were  tied on with string  so you can see this is a big learning curve for me.  Hence some questions on technique.....

First question is how fast ?  This polisher has a range from 2500 to 6500 rpm and the dial gives levels 1-6 with 1 being slowest.  That's quite a range so if yours has similar speed control I'd appreciate any guidance you could give on what speed for what operation or pad.  I know there is plenty of paint to go at but I'm wary of overdoing it so I've only used settings 1&2 so far.

Second - from the picture you posted, are you using your polisher for the 1000/2000 grit paper stage ?  I've previously done that by hand with soapy water (and it takes ages) but are there pads you can get that do the same job with a dry polisher like my new toy ?

Third - I bought a package kit which has 3  Menzerna compounds, Heavy Cut 400, Medium cut 2500 and Super Finish Plus.  3 Hexlogic pads, Orange Medium cut, White medium finish, black finish pad.  This kit was aimed at folks trying to bring back a modern car paint before resale, but given that I'm going to try & copy what you do from a matt finish, does this sound ok or should I have some intermediate pad/compounds ? I would normally use G3 first by hand but that's a paste, not a liquid.

TIA, and I promise not to derail the thread again with more questions.....  ;)

Brian
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,January 06, 2018, 06:25:44 AM
STOP,
Save that heavy cut 400 coumpound, that is very abrasive and may be used , wet and slow .
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,January 06, 2018, 07:11:32 AM
STOP,
Save that heavy cut 400 coumpound, that is very abrasive and may be used , wet and slow .

I googled your polisher , very nice addition to your tool chest.  Stay slow and wet , 3 max till you get comfortable with your cutting agents and pads, and your ability to control it .  It is a learning process for you .

Remember to get the wax off first it will clog up your sanding pads fast .

Your Second question , yes sanding pads wet, to start a 20 year old paint job 1500  never dry. Wipe off till you see all gloss gone after wiping with squeegee pad. It could take five or so passes. Test by hand, then apply that knowledge to your polisher to the rest of an area. Then sand with 2000,3000, 4000 5000 . It shortens up compouding and polishing exponentially.  All done wet . Fill a bucket and keep pads in it as you move around the car. You can mix it up a bit .
Dont push down,  let the disc do the job,or abrasive  compound /polish
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Saturday,January 06, 2018, 09:01:49 AM
Thanks for the tips on paper grits. I've never used such fine papers, I need to get some more learning/searching done !

I'm very wary on pressing hard, one of the MR2's we owned had been "polished" before we got it and there were a couple of areas which looked to me as if they'd been melted, sort of pock marked. That wouldn't polish out, new paint was the only way to fix it and hence I don't want to end up the same way with this.

Having said that, it's remarkably smooth tool to operate even on it's 1st setting. I'm not sure why it needs 6500, it gets a good polish at low speeds, but then again I'm working on areas which I have already polished by hand so there's a good base.

Thanks again, not only for your comments but the inspiration to jump in to something new.  Anything else crops up you think I should know, drop me a line....

Brian
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,January 09, 2018, 04:27:53 PM
Hi Brian,
Let us know on a new thread , Flashy cars.. , you can diy..lol. .looking foward to some pics. Some people say all show no go but I will strive for a balance.
Dakazman
ps. My new phone on the way , and now waiting on a 4 month wait for my bumpers to be re chromed. 
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Wednesday,January 10, 2018, 03:04:35 PM
Tore down my seats  today and won a prize for rust removal. The shells will need some work.  $900.00 bill for rechroming bumpers will slow down progress a little.
Trying to get some painting done but the weather is not cooperating.  I will post more pics soon on progress.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: 4129R on Wednesday,January 10, 2018, 08:08:57 PM
$900.00 bill for rechroming bumpers will slow down progress a little.
Dakazman

Mine cost £240 each plus £120 if they needed straightening out.

They came back as good as new, but they had to weld little tabs on the back of the bumpers to attach the electrodes to, and they had not taken those tabs off (about 1/2" square).
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,January 11, 2018, 05:50:24 AM
4129r no straightening,  just a large EPA disposal fee.

Looks like i will be doing some fabrication work on the seat bottom trays.I will also record demensions to completely rebuild. 
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Thursday,January 11, 2018, 06:09:30 AM
I’m always amazed at how rusted the seats and tracks are when they are INSIDE a hardtop car. By the way, RD sells new metal shells if you don’t want to deal with fabricating your own.
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Thursday,January 11, 2018, 06:15:45 AM
It is ironic, isn't it. On the other hand, there are convertibles that are more weather proof than a Europa.
Title: Re: 1970 s2 0453R Reassembly
Post by: 4129R on Thursday,January 11, 2018, 11:07:19 AM
I have repaired about 4 shells using angle for the edges pop riveted in place, and sheet metal similarly pop riveted. I then bash the aluminium pop rivets as flat as possible for maximum grip.

Then I prime the sheets before sending them to my trimmer who will shortly complete set #7, the last set for me.

Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Thursday,January 11, 2018, 05:40:06 PM
7 sets OMG,
Never say , the last ... your knowledge will help others finish there project , so its the same only different.
dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,January 12, 2018, 03:16:36 PM
I have some dimensions on seat frame and foam for rebuild on a federal s2.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,January 12, 2018, 06:29:15 PM
Seat panels as requested!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Friday,January 12, 2018, 06:36:43 PM
Just checking size, hope this helps your progress.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Friday,January 12, 2018, 11:27:42 PM
This is good info for the S2 owners and the basic principles apply to the TC/TCS owners as well.

I realise it's more work, but when you've finished the seats it would be good to have this info collated into a pdf file as an article for the Technical Section. That way it doesn't get lost in a rebuild thread and you'll be helping future members ?   

(thinks - we really should look at a wiki for this stuff.....)
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Saturday,January 13, 2018, 04:42:53 AM
I will redraw the pdf's . They were more of a sketch, so i apologize for that.Also add some missing dimensions and hidden edges,cut lines , stiffeners. Pictures Too.
dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: RoddyMac on Saturday,January 13, 2018, 05:39:59 PM
dakazman,
Thanks for posting all the sketches and pics, they'll help immensely with my build.

Rod
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,January 15, 2018, 05:37:02 AM
Rod ,
Glad to help , keep us posted on your projects materials , vendors,etc.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Monday,January 15, 2018, 05:51:30 AM
I’m looking forward to seeing how your refurbishment turns out.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,January 15, 2018, 04:09:38 PM
Quick question guys ,
    Do either of the door hinge kits come with the bobbins in the upper and lower door?
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,January 15, 2018, 04:45:10 PM
Both r.d. enterprises (stainless steel copies of the original hinges) and Banks (brass hinge kit of a completely different design) hinge kits contain only hinge bits. The assumption is that the bobbins in the body and the door are in good shape. In fact, the hinges I got from Banks assumed that my body bobbins were worn and the pin part that sits in the body bobbins was too thick so I had to have them turned down a bit so if you get them check the fit first. If there is a problem with your bobbins, you'll have to take care of that first.

I originally bought r.d.'s first before I had heard of the Bank's kit. The Bank's kit seemed to be easier to set up so I used them. Since I only have experience with the Bank's kit, I can't say which is better/easier. The Bank's kit has the advantage that it allows you to take the door off and you'll only have to readjust the height of the door. I'm happy with the Bank's hinges.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,January 15, 2018, 05:55:37 PM
Thanks BDA,
   I was leaning toward the stainless but now may go with the brass since I Have a lot of 1” x3” brass stock to make the bobbins so there won’t be any dissimilar metal corrosion in doors however the stock bobbins are still installed in the body.
  My body bobbins are not worn and a 1/2 rod is a perfect fit.
Dakazman

Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,January 15, 2018, 06:17:58 PM
You bring up a good point about corrosion since aluminum and brass are pretty far apart on a galvanic chart and given the humidity in Florida, that could be an issue. I think there's probably enough relative movement that it shouldn't be a problem. A coating of grease would help with door operation and potential corrosion. Theoretically, stainless steel rubbing together could gall. I wonder if the risks of corrosion are greater than corrosion?

In eighteen years, I haven't found any corrosion.
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Monday,January 15, 2018, 06:57:04 PM
I agree, grease Will help with also being 10 miles to the ocean. ITs a nightmare on my woodworking tools. constantly using Johnson paste wax on any bare metal. I left my centering punches out once and they were covered in rust in a week.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: BDA on Monday,January 15, 2018, 07:14:52 PM
Yup, I can relate. I used to live in New Orleans!
Title: Re: 1970 s2 0453R Reassembly
Post by: dakazman on Tuesday,January 16, 2018, 04:55:02 PM
Found the parts that were holding my doors on ... don’t laugh to hard.
Dakazman
Title: Re: 1970 s2 0453R Reassembly
Post by: EuropaTC on Tuesday,January 16, 2018, 11:06:11 PM
Ten minutes with a wire brush, maybe some new washers and a length of stainless 1/2" rod (304 would be fine) and you're good to go.....     ;)
Title: Re: 1970 s2 0453R Reassembly
Post by: Certified Lotus on Wednesday,January 17, 2018, 03:22:28 AM
Those aren’t so bad. Like EuropaTC said, a little polishing up and your good to go.
Title: Re: 1970 s2 0453R Reassembly
Post by: buzzer on Wednesday,January 17, 2018, 05:28:38 AM
The brass banks kit also allows you to easily set the height of the door. As BDA says they are a tight fit in the bobbins but I just used emery cloth to just take a bit off the brass pins. And I think they are easier to use when taking a door off and on.