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Lotus Europa Forums => Members Cars => Topic started by: Lotus7 on Saturday,June 10, 2017, 10:11:59 PM

Title: My S2 project is now a driver!
Post by: Lotus7 on Saturday,June 10, 2017, 10:11:59 PM
After what seems like many years (well, it actually was many years) I finally have my S2 back on the road. I call it my S2-Z5 as it's a Zetec powered car with an NG3-065 5-speed trans. Here are a couple of pics of the car. I've done just about all of the work myself, and a good friend helped with with the paint job. If you have any questions, I'd be happy to answer them.
Title: Re: My S2 project is now a driver!
Post by: Certified Lotus on Sunday,June 11, 2017, 02:27:13 AM
Wow, that looks great! Very nice job. How about some photos of the engine bay? What size tire's are those? And who makes the deck lid hold downs, those are nice.

You should be very proud of your rebuild. Nothing better than knowing every inch of the car while your driving down the road.
Title: Re: My S2 project is now a driver!
Post by: Clifton on Sunday,June 11, 2017, 05:10:39 AM
 I see a Vintage Air controller, Did you do a/c or just heat? I love how you did the fenders.  The rear kind of reminds me of a Miura. How did you do them?
Title: Re: My S2 project is now a driver!
Post by: BDA on Sunday,June 11, 2017, 05:29:01 AM
Very nicely done!
 :lotus:


I'd love to see more pictures, too!
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Sunday,June 11, 2017, 07:17:03 AM
I see a Vintage Air controller, Did you do a/c or just heat? I love how you did the fenders.  The rear kind of reminds me of a Miura. How did you do them?

Yes, that's a Vintage AC controller. The main unit lives behind the dash with the fan/blower in the front compartment area. Currently it's heat only, but my winter project will be to complete the plumbing for the AC condenser. The compressor is already mounted on the LH side of the engine.

We built the fenders using a lot of balsa wood to create the shape. Then covered it with fiberglass. Removed the balsa and glassed everything to the body of the car.
Title: Re: My S2 project is now a driver!
Post by: Grumblebuns on Sunday,June 11, 2017, 07:20:42 AM
That is one beautiful car, well done. I also see that you are eliminating the bumpers. In my eyes the Europas look so much cleaner without the extra chrome. Did you use S1 doors and hardware or convert S2 doors to S1 specs?
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Sunday,June 11, 2017, 07:23:44 AM
Wow, that looks great! Very nice job. How about some photos of the engine bay? What size tire's are those? And who makes the deck lid hold downs, those are nice.

You should be very proud of your rebuild. Nothing better than knowing every inch of the car while your driving down the road.

No photos of the engine bay yet, still need to do a little clean up in there :)

Tires are 195x45x15 in the front and 195x50x15 in the rear.

The deck lid tie downs are my version of the Odie units that were used on the S1's. I formed the plates out of 314 (IIRC) stainless steel. They attach to the front and rear boots with some small stainless bolts. I also made the little lanyards to keep the pushpins from disappearing at car shows :) Here is another pic of them.
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Sunday,June 11, 2017, 07:31:25 AM
That is one beautiful car, well done. I also see that you are eliminating the bumpers. In my eyes the Europas look so much cleaner without the extra chrome. Did you use S1 doors and hardware or convert S2 doors to S1 specs?

I completely agree that the car looks better without chrome. In addition to leaving the bumpers off, I left the rest of the body clean of any of the normal badges. I also used a black lock strip (originally for the MGB) on the front windscreen.

I gave up on finding some S1 doors, so I modified my S2 doors to match the S1 in the side window area. I also covered the recess in the door that was for the window motor. This year I'll be using the original door panels (still waiting for them) but in the future the inner panel will likely be covered in a single layer of carbon fiber with an padded arm rest in the door recess.
Title: Re: My S2 project is now a driver!
Post by: Grumblebuns on Sunday,June 11, 2017, 08:07:01 AM
Where did you source the pushbutton door mechanism? I'm looking for replacements for my S1.
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Sunday,June 11, 2017, 09:27:52 AM
Where did you source the pushbutton door mechanism? I'm looking for replacements for my S1.

My car was a very early S2 that came with the push button door latches. They looks so much better on a sports car than door handles! I remember you old MGA and reaching inside the door to pull the little rope to open the doors! The button is so much more sophisticated!
Title: Re: My S2 project is now a driver!
Post by: dakazman on Sunday,June 11, 2017, 02:01:11 PM
 Congratulations!
That is one beautiful machine.
Love the plexiglass headlight closeouts, paint scheme, fender-wells, doors,....
Aughh ,love it. Did you step back and say this is my car ???
I'll give you some tissues ...lol
Dakazman
Title: Re: My S2 project is now a driver!
Post by: lotusfanatic on Sunday,June 11, 2017, 10:27:22 PM
WOW!

what a beautiful sight on a Monday morning!

Mark
Title: Re: My S2 project is now a driver!
Post by: Certified Lotus on Monday,June 12, 2017, 03:09:01 AM
Sent a PM on the hood pins.
Title: Re: My S2 project is now a driver!
Post by: Bainford on Monday,June 12, 2017, 08:24:16 AM
Outstanding work! Your Europa is gorgeous. You have an excellent eye for detail, and I just love the bonnet and deck lid hold down fixtures. Very nice work on those. Hats off to you for a great result. It must be nice to now be able to slide behind the wheel and cover some miles. Cheers.
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Wednesday,June 14, 2017, 09:50:26 AM
There seems to be some interest in the front hood and rear deck lid pins that I made. I searched the garage and found two of the three pieced that I used to make the plates. Basically I used a piece of scrap 1.5"x1/8" tube, two plates and a 1.25" steel ball to form my die plate. Material was 22ga 304 stainless steel. I clamped a 3x4"  piece of steel between the two plates them gently pressed the ball into the tube. I did a couple practice pieces until I found the depth that I wanted. After pressing them plates, I used a template to scribe the outline of the plates and make the holes. From there is was just time to cute out the plates, use the belt sander to bring them to the final shape and then drill the three holes.

The part that does not show in the original pictures is the part that mounts to the body. I threaded some 1/2" aluminum bar stock then drilled a 1/4" hole through the center. Added a counter sink on one end and squared off the other end. It needs sharp shoulders on the inside so the push pins will not work themselves out. I also made some aluminum 'nuts' to lock everything in place.

Lots of time for each one, but it's what you expect with custom built, hand made parts!



Title: Re: My S2 project is now a driver!
Post by: jbcollier on Wednesday,June 14, 2017, 03:22:15 PM
Very cool!
Title: Re: My S2 project is now a driver!
Post by: Certified Lotus 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!
Title: Re: My S2 project is now a driver!
Post by: 3929R on Monday,June 19, 2017, 04:03:25 PM
Worth the wait, I'd say! I can't wait to see it up close!
Title: Re: My S2 project is now a driver!
Post by: Keith A on Tuesday,June 20, 2017, 04:34:08 PM
Excellent work! Many many hours but well worth the time and effort, well done!
Title: Re: My S2 project is now a driver!
Post by: Lotus7 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.

Title: Re: My S2 project is now a driver!
Post by: BDA on Sunday,June 25, 2017, 04:35:53 PM
Very nice!
Title: Re: My S2 project is now a driver!
Post by: Bainford on Monday,June 26, 2017, 08:34:12 AM
Yes, agreed. Nice work!
Title: Re: My S2 project is now a driver!
Post by: 3929R on Wednesday,July 05, 2017, 02:03:12 PM
It's even more stunning up close and personal.
Title: Re: My S2 project is now a driver!
Post by: Certified Lotus on Wednesday,July 05, 2017, 03:10:51 PM
Very nicely done! You should be very proud!
Title: Re: My S2 project is now a driver!
Post by: lotusfanatic on Wednesday,July 05, 2017, 10:47:59 PM
truly beautiful!

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

Mark
Title: Re: My S2 project is now a driver!
Post by: TCS4605R 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
TCS4605R
Title: Re: My S2 project is now a driver!
Post by: Chuck Nukem 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?
Title: Re: My S2 project is now a driver!
Post by: Lotus7 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.
Title: Re: My S2 project is now a driver!
Post by: Lotus7 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
TCS4605R

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
Title: Re: My S2 project is now a driver!
Post by: Lotus7 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.

Title: Re: My S2 project is now a driver!
Post by: BDA on Sunday,August 06, 2017, 08:18:38 PM
Very nicely done, Lotus7! It looks like you've done an outstanding job! I'm anxious to hear/see more about your A/C installation as you continue.
Title: Re: My S2 project is now a driver!
Post by: Certified Lotus on Monday,August 07, 2017, 03:45:58 AM
Nice installation. Any idea How much HP from that engine/carb set up?
Title: Re: My S2 project is now a driver!
Post by: Lotus7 on Monday,August 07, 2017, 06:21:33 AM
I've not had it on a dyno so everything is just a guess. Years ago I remember see a lot f incremental mods on a stock Ford Focus engine. With headers similar (or identical?) to the ones I have and individual tb's they saw about 150hp on the dyno. To get more than that they had to do a lot of work to the engine. So my guess would be about 150hp. I'm using stock Ford injectors and an Emerald K3 ECU. I have it in their 'adaptive' mode so it is slowly learning exactly where the injection amounts should be. I have most of the map set to between 13.5 and 14.5 fuel ratio depending on the RPM's and throttle position.