Lotus Europa Community

Lotus Europa Forums => Members Cars => Topic started by: Serge on Thursday,November 29, 2012, 02:58:36 PM

Title: #460002 - Restoration
Post by: Serge on Thursday,November 29, 2012, 02:58:36 PM
Hello everyone,


I'm Serge and I live in Belgium. I've acquired #460002 in October of 2011 and I've been restoring the car slowly. This being the oldest Europa that's known in the registry and by Lotus themselves, I want to restore the car to it's original appearance. But the car isn't a matching number car, because the original engine has been replaced in the past. I'm also preparing the car for FIA Appendix K Historic Racing (Period G2) and therefor all the modifications that I'm making to the car, that aren't original, will be reversible in the future. So I can use the car for Historic Rallies, hill-climbs and races and I can undo all of the modifications in the future so it will retain most of it's value.

I've set up a blog on http://Sleurs-Motorsport.com - here I post all of the progress that make on the restoration. I'll post the small updates on here, so you can click through to my website if you'd like. This are the posts of the past year in chronological order, so it's easier for you to read.

Lotus Europa S1: Barnfind

(http://sleurs-motorsport.com/wp-content/gallery/cache/162__640x480_p1090001.jpg)

I always wanted a car restoration project. I was always researching what car I wanted to restore. First I wanted a mini, then a Karmann Ghia, after this I wanted an MGB, but then I found something that would be a perfect candidate.

http://sleurs-motorsport.com/?p=172


Lotus Europa S1: What’s underneath the dust

(http://sleurs-motorsport.com/wp-content/gallery/cache/177__640x480_p1090020.jpg)

After getting the car home, I wanted to see what’s underneath the layers of dust the car gathered by standing in a dusty barn for 19 years.

http://sleurs-motorsport.com/?p=188


Lotus Europa S1: A place to work

(http://sleurs-motorsport.com/wp-content/gallery/cache/195__640x480_p1090044.jpg)

To be able to restore a car, you need a workshop, preferable a large garage where you have all the room and tools in the world. I had neither.

http://sleurs-motorsport.com/?p=196


Lotus Europa S1: Bloody Knuckles and Broken Dreams, Part 1

(http://sleurs-motorsport.com/wp-content/gallery/cache/199__640x480_p1090085.jpg)

I started disassembly a couple of weekends ago and I had some things to show for it. I had bloody knuckles from parts that didn’t want to come loose, and after the first day of stripping the car down, I knew this project was going to take a lot longer than I first anticipated. But there’s also some good news!

http://sleurs-motorsport.com/?p=204


Lotus Europa S1: Moving the 821

(http://sleurs-motorsport.com/wp-content/gallery/cache/232__480x640_p1090133.jpg)

This post is all about getting my 821 engine down a flight of stairs.

http://sleurs-motorsport.com/?p=219


Lotus Europa S1: Bloody Knuckles and Broken Dreams, Part 2

(http://sleurs-motorsport.com/wp-content/gallery/cache/264__640x480_p1090293.jpg)

The Lotus is disassembled!

http://sleurs-motorsport.com/?p=226


Lotus Europa S1: The Good, the Bad and the Ugly

(http://sleurs-motorsport.com/wp-content/gallery/cache/289__640x480_p1090580.jpg)

It has been a while since the last update, but I haven’t been sitting still. When I last updated the blog, I just had disassembled everything, and the next step was cutting the chassis out of the body. So I’ll talk you through the past couple of months.

http://sleurs-motorsport.com/?p=233


Lotus Europa S1: Sometimes It’s Not as Bad as It Looks

(http://sleurs-motorsport.com/wp-content/gallery/cache/299__640x480_p1090595.jpg)

I got lucky with the chassis! Once all the surface rust was removed, it appeared to be in better shape than I expected!

http://sleurs-motorsport.com/?p=358


Lotus Europa S1: So Many Jobs, So Little Time

(http://sleurs-motorsport.com/wp-content/gallery/cache/303__640x480_p1090835.jpg)

It's been a while since my last update, I had a very busy summer, but I did manage to get some work done on the Europa.

http://sleurs-motorsport.com/?p=374


Chassis repairs, Part 1

(http://sleurs-motorsport.com/wp-content/gallery/cache/316__640h=480x_p1100627.jpg)

So I have started with the chassis repairs, work is going slow, but I’d rather do it slow and correct than have to clean up after myself a couple of years from now.

http://sleurs-motorsport.com/?p=419


The compete URL of my website is http://Sleurs-Motorsport.com So you can follow some more of my progress on there. There's also a subscription function on there now, that way you can get my posts via email instead of having to visit my site know and again. There's a new blog-post coming with a new update, but I haven't had the chance to upload the pictures, but I'll put them online before the end of the weekend, promise!

I've also been working on a Video web series about my restoration, because I like to watch these sorts of video's on the internet, and now I thought it was my turn to make one, so other can enjoy. Please check them out and tell me what you do (and don't) like about them. These are just the first two video's. I have a third one lined up to edit, but they take quite a lot of time to make, so I have to find a couple of hours in my schedule to edit them.

http://www.youtube.com/watch?v=r-J0mdApcQY


http://www.youtube.com/watch?v=OgZSySqUrjc


Kind regards,


Serge

 
Title: Re: #460002 - Restoration
Post by: andy harwood on Thursday,November 29, 2012, 04:47:43 PM
Serge,
Thanks for posting about your restoration.
I have been to you web site a couple of times checking out your progress. Watched your videos also, they were very good.
I'm looking forward to seeing your progress on the frame.
andyh
Title: Re: #460002 - Restoration
Post by: Bainford on Friday,November 30, 2012, 02:22:45 PM
Welcome to the forum, Serge. That's quite a project you have there. I'm looking forward to the updates as they come. Best of luck.
Title: Re: #460002 - Restoration
Post by: cal44 on Friday,November 30, 2012, 03:53:35 PM
Hey Serge,

good thing the engine is near the washing machine..........that baby will clean right up............

A 46.............you lucky man. 

Mike
Title: Re: #460002 - Restoration
Post by: TheKid#9 on Friday,November 30, 2012, 10:11:03 PM
Wow a S1 restoration! Hope to see pictures of the progress you make on it. Good Luck!
Title: Re: #460002 - Restoration
Post by: Lotus46 on Sunday,December 02, 2012, 09:05:42 AM
Hi serge :welder:

Long but very interresting job

I've done a same job after a road crash :confused:

well i'm living not so far from your country, if you need some help

I m waiting for your progressive pics restauration

bon courage
L46
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,December 04, 2012, 08:50:29 AM

Thank you all for your kind comments!


This is a small update! I've removed the strengthening plates for the engine mounts on the chassis, removed the rust and put new plates on.

(http://sleurs-motorsport.com/wp-content/gallery/cache/333__640x480_p1100652.jpg)

The complete update, with a lot of pictures and a bit more explanation is on my blog here: http://sleurs-motorsport.com/?p=471


Kind regards,

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,January 08, 2013, 01:32:06 AM


Hello everyone,


I had some spare time to edit another video segment. This is the video update about the replacement of the strengthening plates that I showed you in the post above.

I hope you'll enjoy it!

This is the video URL:
http://www.youtube.com/watch?v=z9SZGp3_FZ8


Kind regards,

Serge
#460002
http://sleurs-motorsport.com/

Title: Re: #460002 - Restoration
Post by: cal44 on Friday,January 25, 2013, 08:47:01 AM
That a boy Serge......... you are doing well.

Mike
Title: Re: #460002 - Restoration
Post by: Mecky on Friday,February 22, 2013, 05:09:03 AM
Hi Serge,

how is your project going on? Are you already able to guess, when your car could be ready?
The race tracks need every Europa they can get :pirate:

Will you use your 821 engine or replace it by a 697 (maybe the original one)?

Regards

Stefan
Title: Re: #460002 - Restoration
Post by: Serge on Friday,February 22, 2013, 06:56:14 AM

Hi Stefan,


my car will take some time to complete, at least another year, maybe even longer. My ultimate deadline is 2017 (when the car is 50 years old).

I will be using the 821 engine so I can get homologated as a GT car in period G2 for appendix K. I have another 697 engine, but this isn't the original engine (it was replaced by a 697-01 engine from a renault 16 TL). I will probably use the 697 engine to make this engin to original spec, so I have an original spec engine with the car, should I want to change from the racing engine.

Kind regards,

Serge


PS: I have at least 2 video / blog updates coming in the next couple of weeks.

Title: Re: #460002 - Restoration
Post by: Serge on Sunday,March 24, 2013, 02:07:24 PM
Hi everyone,


I have another video for you, however there isn't much Lotus content, but there is quite a lot of footage of the manufacturer-stores in Paris and of the Rétromobile Classic Car Show in Paris (One of the bigger shows in Europe, and the first event of the new classic car season).

I am currently editing three other videos, so expect to get some more Europa-oriented updates very soon.

I hope this video bridges the gap.

http://www.youtube.com/watch?v=rcPbBipyhO4 (http://www.youtube.com/watch?v=rcPbBipyhO4)

Kind regards,

Serge
#460002
Http://Sleurs-Motorsport.com (http://Http://Sleurs-Motorsport.com)
 
Title: Re: #460002 - Restoration
Post by: Serge on Monday,March 25, 2013, 09:24:45 AM
I've been able to upload some pictures of my repairs to the rear crossbar and some of the modifications that I made to the rear Y-section of the chassis. There will also be a video about these repairs, but that will take another few days before I can get that online.

(http://sleurs-motorsport.com/wp-content/gallery/cache/350__640x480_p1100726.jpg)

Meanwhile you can read all about it right here:

http://sleurs-motorsport.com/?p=535 (http://sleurs-motorsport.com/?p=535)

Kind regards,

Serge
#460002
http://Sleurs-motorsport.com (http://Sleurs-motorsport.com)
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,April 17, 2013, 04:58:48 AM


(http://sleurs-motorsport.com/wp-content/gallery/videoseries/rearcrossbar.png)

Finally I've found some time to edit the video of the repairs above. I had already edited the next video, so I'll upload that in a couple of days.

I hope you'll enjoy it:

http://www.youtube.com/watch?v=qyP5Zg-OPqA


Kind regards,

Serge
#460002
http://Sleurs-Motorsport.com
Title: Re: #460002 - Restoration
Post by: LotusJoe on Wednesday,April 17, 2013, 10:16:00 AM
Serge, Maybe I'm having some difficulty on my end but it seems you latest video is only about 1 minute long, and ends while you explaining the cross member modifications.  :confused: But what I'm really interested in, is where can I get the t-shirt your wearing? Very cool.

Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,April 17, 2013, 10:34:50 AM

Hi Joe,

the video seems to be working on both of my computers, if the problem remains, try to watch the video in another quality (480p, 360p, ...). There could be a problem with the youtube encoding, I'll try to look into it.


The T-shirt that I'm wearing is a T-shirt with the Pistonheads logo on, this was a T-shirt given at the Spa 6 Hours Historic race meeting a couple of years back. But they sell T-shirts with the same logo (and many much cooler car-related shirts) on their website:

http://www.shotdeadinthehead.com/what/mens-tees/collection/pistonheads

If you have any questions about the crossmember modifications, just post them here and I'll answer them as good as I can.


Kind regards,

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Friday,April 19, 2013, 01:54:38 PM

Hello everyone,

I've uploaded aforementioned video. In this video I’ll show you some of the parts that I have been collecting for the past year to be able to continue and finish my restoration. This ranges from paints, tools, fasteners to second hand difficult to find Lotus parts. I also bought a lot of parts to build my own engine mounts, lower links and radius arm mounts. Since I recorded this video, I have been able to buy a Lotus Europa steering wheel, however, this isn't the exact steering wheel that I wanted, but it was fairly cheap and it could be used without looking too much out of place.

You can watch the new video on my blog here:

http://sleurs-motorsport.com/?p=558

Kind regards,

Serge
#460002
http://Sleurs-Motorsport.com

Title: Re: #460002 - Restoration
Post by: Serge on Friday,July 19, 2013, 03:19:23 PM

Hi everyone,


This is a small update for my Europa project. I've made an S2 modification to my S1 chassis, specifically the strengthening plates around the radius arm mounts.

(http://sleurs-motorsport.com/wp-content/gallery/cache/366__640x480_p1100745.jpg)

There's a complete explanation with lot's of photographs on my blog on the link below and underneath I'll place a link to a youtube video where I explain and document the upgrades.

Blog: http://sleurs-motorsport.com/?p=575

Video: http://www.youtube.com/watch?v=DG2oQscv5KA


Kind regards,

Serge
#460002
http://sleurs-motorsport.com/
http://youtube.com/sleursmotorsport

Title: Re: #460002 - Restoration
Post by: EuropaTC on Friday,July 19, 2013, 10:37:36 PM
It looks a sensible idea Serge. While you're at the "reinforcing" stage I'd also suggest the engine mount area for serious inspection. On my old chassis they had deteriorated badly and were the main cause for the body removal. Although it was largely corrosion I also found cracks which I suspect was caused by flexing of the area behind the engine mounts. At the stage you're at it would be very easy to do a similar treatment to that area.

Brian
Title: Re: #460002 - Restoration
Post by: Serge on Saturday,July 20, 2013, 03:08:49 AM

Hi Brian,


The reinforcing plates for the engine mounts were very rusty as well on my chassis. Quite a lot of rust had developed between the spotwelded plates. I removed the plates and made my own before welding them back on.

(http://sleurs-motorsport.com/wp-content/gallery/cache/328__640x480_p1100619.jpg)

Video of those repairs: http://www.youtube.com/watch?v=z9SZGp3_FZ8


Kind regards,

Serge
Title: Re: #460002 - Restoration
Post by: EuropaTC on Saturday,July 20, 2013, 10:57:35 PM
Hi Serge,

That's the bit !   I've found a picture of what mine looked like when I stripped the car and most of the damage was just outside of the mount. 

I was puzzled why you would get corrosion on a vertical plate where water would run away and there was nothing to hold moisture in place (mud/bodywork/noise insulation felt/etc). I ended up with the theory that it was down to the engine mount loading from cornering which would cause the vertical section to deflect, break the paint coating & allow gentle rusting.

My memory is hazy but I seem to recall welding in sections and making a longer & more rigid strengthener to try and spread the load better.

Brian 
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,September 19, 2013, 10:15:08 AM

Hello everyone,


I've finally had some time to upload some pictures of my recent work and to write some comments about them. The pictures were taken between may and august so they span a few months working on and off on the chassis.

The rusted metal was cut out and replaced with new steel sheets that were folded to match the original panels. Everything was then painted in Epoxy-Mastic paint to get the best rust protection out there. After the front T-section is welded on, I will paint the chassis again with satin black 2K paint, to get better aesthetics.

Currently I'm working on building a new front T-section from scratch, all the panels are cut, but I need to fold a couple of them and then I need to weld them together.

If I can find some time in the coming week, I'll edit the video of these chassis repairs and I'll upload it to youtube.

These are some before and after pictures. You can read all about the repairs on my blog (link below), where you can find a report with 55 photographs and a step-by-step explanation of everything that I did.

Before:

(http://sleurs-motorsport.com/wp-content/gallery/cache/375__640x480_p1100767.jpg)

After:

(http://sleurs-motorsport.com/wp-content/gallery/cache/428__640x480_p1110120.jpg)

Blog: http://sleurs-motorsport.com/?p=581 (http://sleurs-motorsport.com/?p=581)

Kind regards,


Serge
Title: Re: #460002 - Restoration
Post by: LotusJoe on Thursday,September 19, 2013, 10:40:33 AM
Serge,
Project is looking fantastic.  :trophy:
Title: Re: #460002 - Restoration
Post by: Bainford on Friday,September 20, 2013, 08:40:26 AM
I must say, Serge, that I'm quite impressed with what you've taken on, and the excellent work you are doing. Quite inspiring.
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,October 03, 2013, 03:40:25 AM

Thank you all for the kind replies!

I have managed to edit one short video, but I have two more lined up, I just need to find the time!

In this short video I’ll show you my ‘new’ S1 steering wheel and ashtray and I tell you the story of how I got it. I’ll also show you the difference between an S1 and an S2 steering wheel.

If there is any interest in me making another ‘Collecting parts’-video about all of the difficult (or not so difficult) to find parts and components that I have collected over the past few months, let me know and I’ll make another one if I find the time.

The link is below the photograph!

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/steeringswap.png)

http://www.youtube.com/watch?v=wdU4gNnqUUA


Kind regards,

Serge

Blogpost: http://sleurs-motorsport.com/?p=588
Title: Re: #460002 - Restoration
Post by: Serge on Monday,December 02, 2013, 10:19:16 PM
Finally a new video!

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/backbonechassis.png)

https://www.youtube.com/watch?v=kqBmgBixX2s

The blogpost isn't up yet and I still need to rewrite the description, but you can already watch it.


Kind regards,

Serge

Title: Re: #460002 - Restoration
Post by: Mecky on Tuesday,December 03, 2013, 01:15:59 AM
Great Job, Serge!  :pirate:
Title: Re: #460002 - Restoration
Post by: Serge on Monday,December 23, 2013, 02:26:27 PM

Thanks Stefan!


I've uploaded some more pictures to my website and a complete explanation on how to make adjustable lower links:

http://sleurs-motorsport.com/?p=599 (http://sleurs-motorsport.com/?p=599)

There's also a video on the way about the entire process.


(http://sleurs-motorsport.com/wp-content/gallery/lowerlinks/p1110273.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/lowerlinks/p1110277.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/lowerlinks/p1110326.jpg)


Hopefully this will be of use to somebody.


Kind regards,


Serge
Title: Re: #460002 - Restoration
Post by: Chuck Nukem on Monday,December 23, 2013, 10:43:16 PM
Serge that looks excellent!! I am planning to make a similar upgrade for mine.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,December 30, 2013, 10:57:13 AM

I have been able to upload the video about the making of the lower links! It has turned out to be a little bit longer than I wanted, but I wanted to be thorough in my explanation so you could use the video as a guide to make some of your own.

I'll promise to make some shorter, less technical videos in between the long-winded technical restoration videos if I find the time.

Youtube:
http://www.youtube.com/watch?v=LNIELWMgKJk

Blogpost:
http://sleurs-motorsport.com/?p=605

Enjoy!

Title: Re: #460002 - Restoration
Post by: cal44 on Monday,December 30, 2013, 12:46:53 PM
Nice work Serge.  I'm building a big ol' fence in my backyard........are you available?............ :FUNNY:

mike
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,February 02, 2014, 04:13:20 PM
Hi everyone,


After my exams the university decided that I deserved a week off, so I found some time to work on the Europa and also update my blog!

I finally wrote very lengthy blog post with 60+ photographs of the fabrication of the front T-section.

This is a teaser picture:
(http://sleurs-motorsport.com/wp-content/gallery/tsection/p1110510.jpg)

You can read the entire story right here:
http://sleurs-motorsport.com/?p=609 (http://sleurs-motorsport.com/?p=609) 


I hope you'll enjoy it.

Kind regards,

Serge

Title: Re: #460002 - Restoration
Post by: Chuck Nukem on Monday,February 03, 2014, 07:09:40 AM
A masterclass! I am following in your footsteps.
Title: Re: #460002 - Restoration
Post by: andy harwood on Monday,February 03, 2014, 06:10:07 PM
Serge,
that is some fantastic work you're doing.
the phrase 'better than new' comes to mind.
thanks for taking to document & post your progress so thoroughly.
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,February 20, 2014, 02:40:52 AM
Thank you for the kind comments everyone. I've split the T-section video up in to parts because it was to lengthy otherwise. The first part is uploaded and the second part will be online before the end of next week.

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/tsectionfabrication.png)

In this first video I'll explain the fabrication of all of the panels, while in the second video I'll show you how I welded them all together and how I got the suspension geometry right.

Link to the video:
http://www.youtube.com/watch?v=DztlXXHQwyo (http://www.youtube.com/watch?v=DztlXXHQwyo)

Link to blog:
http://sleurs-motorsport.com/ (http://sleurs-motorsport.com/)


Kind regards,

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Friday,February 28, 2014, 03:17:31 AM
Here is the second and final part of the video on the front T-section.

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/tsectionfinal.png)

Link to the video:
http://www.youtube.com/watch?v=2w7iyrgfdew (http://www.youtube.com/watch?v=2w7iyrgfdew)

Link to the blogpost:
http://sleurs-motorsport.com/?p=644 (http://sleurs-motorsport.com/?p=644)


Kind regards,

Serge

Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,March 11, 2014, 03:39:26 AM
(http://sleurs-motorsport.com/wp-content/gallery/videoseries/polishingbumpers.png)


This is the first in a series of short videos that I will try to make to keep the momentum going.

These videos will be shorter, less in depth videos on smaller jobs on the restoration of my Lotus Europa S1 that don't take up a lot of time to do and film. I will be releasing these in between all of the longer videos that take a lot of time to make.

This first video will be on the polishing of the original 1967 bumpers that had a really hard life. I will be trying out the 'cola and aluminium-foil'-method as well as polishing the bumpers with Autosol metal polish.

Link to the video:
http://www.youtube.com/watch?v=wZiSK4aqFOk (http://www.youtube.com/watch?v=wZiSK4aqFOk)
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,March 26, 2014, 05:57:37 AM
If only my turtle would care to cooperate..
Title: Re: #460002 - Restoration
Post by: BDA on Wednesday,March 26, 2014, 07:46:11 AM
 :FUNNY:
Title: Re: #460002 - Restoration
Post by: 3929R on Wednesday,March 26, 2014, 08:07:01 AM
 :FUNNY: :beerchug:
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,April 03, 2014, 10:21:21 AM
Update!

(http://sleurs-motorsport.com/wp-content/gallery/finishingchassis/p1110595.jpg)

Blogpost on welding the T-section to the backbone:
http://sleurs-motorsport.com/?p=659 (http://sleurs-motorsport.com/?p=659)


I'm running behind on the updates, front suspension and front brakes are already done!

The video for this update will be online soon. I'm trying to keep to a rythm of one video for every two weeks, but I'm struggling to find time to edit them..


Hold tight!

Serge
Title: Re: #460002 - Restoration
Post by: jbcollier on Friday,April 04, 2014, 07:41:00 AM
Looks great Serge!  Just a couple of points:

- the chassis corrodes mostly from water trapped between the body and the chassis on S1s.  They corrode from the outside in rather than the inside out.

- it is moderately easy to seal up the front of the chassis but water mainly makes its way to the front of the chassis from the rear!  It splashes in through the rear wheel wells and flows down and forward.  When you put the chassis back into the body, make sure you carefully seal the chassis to the body at the rear at roughly the line of the seat backs.  Fibreglass over a strip of foam to create a barrier to the water flowing further forward and drill a few drain holes in the low points to keep it from building up.

- water also finds its way onto the rear chassis rails through the engine hood vent holes.  Again, use carefully placed "dams" to direct this water from flowing further in.  You want to direct it down and out your body drain holes.

- finally your carefully sealed chassis will be drilled full of holes when you rivet it back in place.  Sealer inside and, more importantly, on the underneath is very important, as well as checking and refreshing it on a regular basis.  Inside use a sealer/corrosion inhibitor that stays semi-liquid so it can flow in and around where it needs to.  Underneath, use a sealer that hardens but not too much, otherwise it will crack and let moisture through.
Title: Re: #460002 - Restoration
Post by: Serge on Friday,April 04, 2014, 08:57:45 AM
Thanks!

Did not know the water flowed from the rear to the front, interesting to know!

I was trying to prevent having to use a cavity wax for the inside of the chassis because it creates a real mess and I will have to stick my hand in there in the future to install and adjust various things. However, once everything is settled I can still apply it afterwards.

Serge

Title: Re: #460002 - Restoration
Post by: Serge on Saturday,April 19, 2014, 04:07:26 AM
I've uploaded the video about the final fabrication on the chassis. The chassis has been completely finished at this point.

https://www.youtube.com/watch?v=HYr6EEvjjuY (https://www.youtube.com/watch?v=HYr6EEvjjuY)


Upcoming videos:
explaining my spray painting setup
front suspension
brake calipers
rear radius arm mounts
rear suspension

Enjoy,

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,April 29, 2014, 11:48:36 AM
(http://sleurs-motorsport.com/wp-content/gallery/videoseries/spraypaintingequipment.png)

I've uploaded another short video. This time I'll show you the spray painting equipment that I plan to use to do all of the painting on my car.

https://www.youtube.com/watch?v=clIS8a2_KZw (https://www.youtube.com/watch?v=clIS8a2_KZw)


Enjoy & Share!

Serge
Title: Re: #460002 - Restoration
Post by: 3929R on Tuesday,April 29, 2014, 01:12:16 PM
 :coolpic:  Interesting.  I look forward to seeing how much of a learning curve there is for the equipment.  You need my bad looking old truck to practice on. I'll drive it over to you. 
Title: Re: #460002 - Restoration
Post by: BDA on Tuesday,April 29, 2014, 07:04:49 PM
Another great video, Serge! I like the idea of taking the cross member out without totally dismantling the rear suspension but I don't think it will be as useful as you might think. Remember that the suspension links (the lower and the half shaft) are attached to the tranny anyway so you'll obviously have to disconnect them and at that point, the car won't be able to stand on its own. If you install a twin link rear suspension, you could fabricate a piece to bolt to the lower rear suspension arms then with your 'detachable' cross member, you might be able to do it.

If you still want to do your cross member that way, you could weld a box or pair of flanges that fits inside the ID of the cross member box on the shock ears. Then cut the bottom out of the cross member box section so that it slips over the box or flanges welded to the shock mount ears. Then bolt the cross member to the flanges or inside box. It's probably harder to describe than do it. I'm sure you get the idea.

Keep up the good work and the videos!!!

BTW - I forgot to say that I didn't have any trouble watching the whole video. :-)
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,April 30, 2014, 01:11:33 AM
Thanks everyone!

BDA, you are completely right!

Some of the twin-link cars or the cars with the spyder-rear-wishbone setup have this removable crossmember, because they can. I had figured it out afterwards that it wouldn't make a difference, because everything is connected anyway. So I decided to leave it like it is and not make it removable.

Serge

 
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,May 22, 2014, 02:47:05 AM
New update! Taster:

(http://sleurs-motorsport.com/wp-content/gallery/cache/571__640x480_p1110657.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/cache/593__640x480_p1110743.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/cache/619__640x480_p1110824.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/cache/622__640x480_p1110829.jpg)


Very long blogpost about the restoration of the front suspension, 50+ pictures.

http://sleurs-motorsport.com/?p=679 (http://sleurs-motorsport.com/?p=679)


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,August 21, 2014, 03:09:11 AM
(http://sleurs-motorsport.com/wp-content/gallery/videoseries/wishbonesuprights.PNG)

New video!

I wanted to make a single video, but it turned out that I had a lot more footage than I thought. In stead of releasing one single hour long video, I’ll be releasing four shorter videos for your viewing pleasure. This is the first of four on the front suspension. Afterwards I have videos coming on the front calipers, competition rear radius arm mounts, rear suspension, engine mounts, ...

In this video I strip, clean, paint and reassemble the front wishbones and uprights. In the next video we’ll talk about the restoration of the front hubs.

Link to video:
https://www.youtube.com/watch?v=8IpdF5VWFyo (https://www.youtube.com/watch?v=8IpdF5VWFyo)


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Thursday,August 21, 2014, 08:06:29 AM
Good job, Serge!

I would suggest that a sandblaster that you hook to an air compressor would be a good way of getting the grung, rust, and old paint off those bits. It also gives a rough surface that is good for painting.

I know editing those videos must be a major ordeal. I've already done the stuff you're working on, but I still enjoy them. Keep up the good work!
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,August 21, 2014, 08:27:13 AM
Thanks!

Yes, an air compressor and sandblaster would be very useful tools, but I have neither, and don't want to invest too much if I can do it by hand too. My time doesn't cost me anything, and being a student, I don't make any money either. So I rather spend a day extra cleaning everything by hand if that means that I can buy another part for my Europa.

The easy way would be to have it powder coated, they sandblast everything before they powder coat it. Two birds with one stone, but not the satisfaction of knowing that you've all done it yourself (and saving quite a bit of money doing so).

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Friday,September 05, 2014, 03:12:26 PM
(http://sleurs-motorsport.com/wp-content/gallery/videoseries/fronthubs.PNG)

The second video in the series of four on the restoration of the front suspension. In this part I restore the front hubs, install new wheel studs and new wheel bearings.

Enjoy!

https://www.youtube.com/watch?v=HnidVlAaKCw (https://www.youtube.com/watch?v=HnidVlAaKCw)


Serge
Title: Re: #460002 - Restoration
Post by: BDA on Friday,September 05, 2014, 07:31:45 PM
Another great video, Serge.

I would make two suggestions. I usually put a nut at the end of a threaded piece to help make sure the threads aren't damaged. I realize, however, that for the studs, there is little chance of messing up the threads. The other is because of the weird shape of the grease cap, I had a 10-32 nut tacked inside the cap. Now if/when I need to take the cap off, screwing a long screw into the hole in it will easily push it out.

Thanks for the videos, Serge and keep up the great work! Good luck with the restoration!
Title: Re: #460002 - Restoration
Post by: Serge on Saturday,September 06, 2014, 12:38:02 AM
Thanks, BDA!

You are correct on protecting the threads, the nuts have been on there since after the video, but I should have put them on earlier to protect them while installing the bearings. The new grease caps that I have (not shown in the video) have a small hole on the front, and I use a wood screw to thread into the hole and pull the cap off.
Title: Re: #460002 - Restoration
Post by: BDA on Saturday,September 06, 2014, 11:14:42 AM
Great minds think alike!  ;D
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,September 30, 2014, 09:05:33 AM
Hi everyone!

I've met up with some fellow S1 owners last week here in Belgium (#40 and #70). #70 was restored in the '80s and has a crossflow engine, #40 has been rescued from a lockup somewhere in Belgium after been stored there in the 1970's. It has had a new front end grafted on from an S2 after an accident, but otherwise it is in surprisingly original condition. It will be restored in the next few years. The owner has a very nice collection of cars, including a Lotus XI, Lotus 340R, Lotus Elise S1, a Lola T212 and a Lancia Fulvia Zagato. He used to have a Lotus 47 and Lotus Elite Type 14.

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/frontarb.PNG)

In the meantime I've also edited another segment of the front suspension rebuild. In this video I'll work on the front anti-roll bar.

https://www.youtube.com/watch?v=DSy7O6yoAfo (https://www.youtube.com/watch?v=DSy7O6yoAfo)


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Tuesday,September 30, 2014, 12:10:03 PM
Another nice video, Serge!

I cheated and cut the lower ring of the drop link in half and had four small tubes welded on either side of both halfs to allow me to bolt them together. I left the top bushes in. They looked in decent shape but beyond that, the looked like they were crimped into the drop link.

Those polyurethane bushings are the way to go!
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,September 30, 2014, 12:33:21 PM
Although I am really happy with the outcome of the poly-bushes in the droplinks, I will be relocating the ARB to just above the steering rack in the future. I have already collected all the parts needed to do this conversion. There are several reasons to do this. The main one being not having to deal with the studs on the end of the front shocks. There are several known cases of people having to replace the studs because they broke off and the roads in Belgium aren't the best. I will be using expensive aluminium monotube shocks and I don't want to risk them or the studs that they would have. With this relocation I will be able to get the shocks without the studs. The second benefit will be the addition ground clearance, because the front ARB is the lowest part of the car. 

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Tuesday,September 30, 2014, 02:20:22 PM
Good idea!

The first Europa I had had a broken stud on one of the shocks. Nothing to do then except buy a new shock.
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,October 02, 2014, 04:00:04 AM
Thanks, BDA!

The last video in the series on the front suspension. Glad I've finally edited it all. Next up will be the rebuild of the front calipers.


https://www.youtube.com/watch?v=oXZH_XUzJu8 (https://www.youtube.com/watch?v=oXZH_XUzJu8)


Serge
Title: Re: #460002 - Restoration
Post by: BDA on Thursday,October 02, 2014, 06:47:45 AM
Another great video, Serge! Good that you mentioned the big washers to keep the bushing from getting pushed out of the A-arm pieces. That happened to me!

With regard to lubing the trunnions. There has been some discussion about using grease vs oil on the yahoo group. I would say that although the manual specifies 90 wt gear oil for the trunnions, that moly grease is better in this application. I have a friend who worked at Shell Oil for twenty five years and although he didn't work with formulating or testing oils and greases, (he did work several years at a grease plant that at the time made half the grease in the world!) he kept up with it pretty closely so he is the guy I go to with most lube issues. I asked him for his advice for lubricating the trunnions and here's what he told me:

Quote
First things first: Use a lithium 2 hydroxystearate grease with moly in it.  Virtually all modern greases with moly are lithium 2 hydroxystearate, so if you get a good moly it will work just fine. Moly is important for your application because it is the ideal lube for sliding friction.  Grade 2 grease outperforms 90W gear oil in every respect since it has low shear, high film strength, and won't seep away over time (plus it works in grease guns).

All of that isn't to say that gear oil is wrong - that's what's in the workshop manual! - but that moly grease should provide better lubrication in this application. It also would not surprise me to find that the manuals predate the availability of moly grease!

Anyway, thanks again for a great video. If you continue with them, it will make it easier for the next restorer!
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,October 15, 2014, 02:49:14 PM
New blogpost!

Restoration of the front calipers!

From this:

(http://sleurs-motorsport.com/wp-content/gallery/calipers/P1090829.jpg)

To this:

(http://sleurs-motorsport.com/wp-content/gallery/calipers/P1120950.jpg)

Link:
http://sleurs-motorsport.com/?p=1357 (http://sleurs-motorsport.com/?p=1357)


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Wednesday,October 15, 2014, 08:22:26 PM
Fabulous write-up, Serge!!! I was going to attempt a similar rebuild when I started on my car many years ago but ended up getting Richard's vented front disc kit so I didn't need to. I may give it a try so I can sell them and your experience will be very useful! Thanks!
Title: Re: #460002 - Restoration
Post by: LotusJoe on Wednesday,October 15, 2014, 08:42:11 PM
Serge,
Great job!! I would have just thrown those old calipers in the trash. Good save  :beerchug:
Title: Re: #460002 - Restoration
Post by: Bainford on Thursday,October 16, 2014, 05:12:33 AM
Wow! Great save. Nice work Serge.
Title: Re: #460002 - Restoration
Post by: Grumblebuns on Thursday,October 16, 2014, 10:45:53 AM
Very helpful write up. When I did my caliper rebuild awhile back, I elected not to split my calipers. That probably made the job doubly difficult but was achievable. The hardest part was getting the old pistons out. Three of the four came out with compressed air, the fourth was stuck pretty bad. I first tried one of those brake piston removal tools. I could get the piston to rotate a couple of degrees in the bore but did not have enough leverage to pull it out. I finally had to resort to using the front brake hydraulics to push the piston out.

For my next caliper rebuild, I'll have to find some of that brake grease to protect the bore and piston from corrosion.

Joji Tokumoto
Fallbrook, Ca   
Title: Re: #460002 - Restoration
Post by: Serge on Monday,October 20, 2014, 02:55:59 PM
I'm being featured on CarBuildIndex.com with my restoration blog and video series!

http://www.carbuildindex.com/34991/reader-submission-a-very-special-1967-lotus-europa-s1-restoration/?utm_campaign=twitter&utm_medium=twitter&utm_source=twitter (http://www.carbuildindex.com/34991/reader-submission-a-very-special-1967-lotus-europa-s1-restoration/?utm_campaign=twitter&utm_medium=twitter&utm_source=twitter)
Title: Re: #460002 - Restoration
Post by: BDA on Monday,October 20, 2014, 03:14:34 PM
That's wonderful!!! You are getting the recognition you deserve!  :trophy:  :beerchug:
Title: Re: #460002 - Restoration
Post by: LotusJoe on Monday,October 20, 2014, 08:05:33 PM
 :trophy:
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,January 27, 2015, 09:32:28 AM
I've finally found some time to edit another video!

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/brakecalipers.PNG)

In this video I'll show you how to bring a set of Girling 14LF calipers back from the dead. These were very rusty and I was doubtful if they could be saved, but they look near perfect when I was done with them. These are the original 1967 calipers that were on the car since it was new.

Link:
https://www.youtube.com/watch?v=UUJuW6Ho2LY (https://www.youtube.com/watch?v=UUJuW6Ho2LY)

Enjoy!
Title: Re: #460002 - Restoration
Post by: BDA on Tuesday,January 27, 2015, 11:26:00 AM
Another great video, Serge!! I did note that you said you used POR15 but the can said POR 20!  :)

Hopefully, when they get hot, the bubbles won't return.

Thanks for the great how-to for restoring brake calipers. Well done!
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,January 27, 2015, 11:49:05 AM
Good eye, BDA! The POR20 is the heat resistant version of the POR15, but I'm not impressed. I do fear the bubbles coming back. If so, I'll paint them with something else, or have them zinc plated.


Serge
Title: Re: #460002 - Restoration
Post by: Serge on Saturday,January 31, 2015, 08:30:42 AM

(http://sleurs-motorsport.com/wp-content/gallery/competitionradiusarmmounts/P1120025.jpg)

I've written a quick blog post and added +/- 20 pictures about the 'competition' radius arm mounts that I built last year.

They replace the original rubber mounts with a spherical bearing.

http://sleurs-motorsport.com/?p=1417 (http://sleurs-motorsport.com/?p=1417)


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Saturday,January 31, 2015, 08:57:00 AM
Great write up and great modification! The way Lotus designed that joint always seemed shoddy to me. This is a big improvement!
Title: Re: #460002 - Restoration
Post by: jbcollier on Sunday,February 01, 2015, 06:02:03 AM
I am NOT a suspension design expert but I do recall reading that the large rubber mount was used to cure some wicked high-speed handling traits.  There are HD versions of the mount available.  Why not ask Richard?  Just don't want your obit reading "Exited stage left, pursued by a Europa."
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,February 01, 2015, 06:24:28 AM
One thing that they changed from the early cars to the later cars was mounting the rubber to the inside of the chassis in stead of on the outside face. They did this because this changed the toe of the rear suspension and this cured some high speed handling issues. I've accounted for this change and the toe is easily set by adding or subtracting washers in this new setup.

Richard at Banks sells his own version of these spherical bearing mounts, so the inherent design is OK I think.


Serge
Title: Re: #460002 - Restoration
Post by: jbcollier on Sunday,February 01, 2015, 07:06:41 AM
Richard's the man.  Just wanted to make sure.
Title: Re: #460002 - Restoration
Post by: BDA on Sunday,February 01, 2015, 10:10:02 AM
Richard IS the man!

Jensen Motors used the same idea but a different implementation in their TCS race car for SCCA C Production. They added a bracket to the frame for the trailing arm attachment to give it double shear and modified the trailing arm to take a rod end at the leading end.
Title: Re: #460002 - Restoration
Post by: EuropaTC on Sunday,February 01, 2015, 11:50:46 PM
Yes, now you mention it I remember the Jensen Motor's conversion. The disadvantage with their method is that it's a major mod on the arm and not so easy to go backwards should you decide you didn't like it.   I think it's ok for race or  track but not something I'd consider for a road car.  At least with Serge's idea it's just a case of bolting in the standard or polyurethane bush.

I suspect the reason there's so much rubber in the mounts is to reduce noise and vibration, I can't see any other reason why they'd use such a large bush when they'd know the amount of movement they'd get on the suspension arm. I guess it's all down to what you want the car for and how you drive it ?

Brian
Title: Re: #460002 - Restoration
Post by: BDA on Monday,February 02, 2015, 07:04:29 AM
Could be. My thought was that it was they got a good deal on a lot of them!  :) I never understood how they devised that. The bush in the trailing arm is oversized for the bolt that fits the rubber bush.  :confused:

The Jensen solution is technically better because that bolt is in double shear rather than single, but from the pictures, it looks like the range of toe adjustment is a lot smaller. I think Richard's/Serge's solution is better for a car that would be driven on the street for that reason as well as it it could be brought back to the stock configuration easier (except that Serge said he's going to drill out the bush in the trailing arm). I also don't think there is a serious problem with the bold bending so the practical difference is negligible.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,February 02, 2015, 07:54:39 AM
There are some things that were brought to my attention that I will have to look into once it's all finished.

Firstly the reason for the big bush: When tightening the big bolt holding the trailing arm on, the rubber will expand a bit and grip the circumference of the big hole in the chassis. Apparently this will help to fix the bush to the chassis, because the two bolts holding the mount in wouldn't be strong enough on their own.

- Now, I'm not so sure of this, but it looks to be a reasonable explanation, anyone has any views on this?

The second thing that I need to be careful of, is that there are some shear strengths that will be going towards the circlip holding the bearing in. I'm not sure how much strength there will be applied in this direction, or how much this circlip can take.

- This we'll only be able to find out once the car is driving, and it could be an issue.


This is one of those times that I'm quite glad that all the modifications that I make are easily reversable. There are a lot of experimental pieces on this car and there will be some that will not work as well as intended.

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Monday,February 02, 2015, 09:18:37 AM
I just checked the documentation on my old Lola T492 S2000 race car and the spherical ball joints on the upper and lower front A-arms were, as I thought, retained by circlips. A wide washer that allows enough misalignment in the ball joint on your set up, Serge, might be a good safety feature.
Title: Re: #460002 - Restoration
Post by: EuropaTC on Monday,February 02, 2015, 09:19:42 AM
  (edited/part quote)
Firstly the reason for the big bush: When tightening the big bolt holding the trailing arm on, the rubber will expand a bit and grip the circumference of the big hole in the chassis. Apparently this will help to fix the bush to the chassis, because the two bolts holding the mount in wouldn't be strong enough on their own.

- Now, I'm not so sure of this, but it looks to be a reasonable explanation, anyone has any views on this?

The second thing that I need to be careful of, is that there are some shear strengths that will be going towards the circlip holding the bearing in. I'm not sure how much strength there will be applied in this direction, or how much this circlip can take.
Hi Serge,

I'm not sure on the expansion theory because the bush has a steel insert which will limit the amount of compression on the rubber -  the big washers will nip it and then stop further compression/expansion.  My assumption why Lotus stipulate the thick large diameter washers either side of the rubber is to hold everything together should the steel insert disbond or pull free ?

I've never really thought too much about the loads in that area, my first guess is that it's mainly fore & aft during acceleration & braking along the axis of the car, which would place the two smaller bolts almost in shear.  A slight bending moment on the chassis given the angle, but I wouldn't have thought it enough to break the bolts, more likely to distort the thinner chassis section if anything.

I think your mod will be fine, your work is excellent and it all looks well engineered.  I have no idea about the security of the circlip, my thoughts would be to sandwich the joint either side with large washers, not enough to limit movement/adjustment, but large enough that should the joint fail, it won't all fall apart in similar vein to Lotus and the OEM rubber bushes.  (that would be rather upsetting if you were driving at the time  ;)   )

Brian
Title: Re: #460002 - Restoration
Post by: EuropaTC on Monday,February 02, 2015, 09:21:16 AM
I just checked the documentation on my old Lola T492 S2000 race car and the spherical ball joints on the upper and lower front A-arms were, as I thought, retained by circlips. A wide washer that allows enough misalignment in the ball joint on your set up, Serge, might be a good safety feature.

 :)

great minds think alike !  You must have posted that last comment while I was still struggling with the spil-chucker.....
Title: Re: #460002 - Restoration
Post by: BDA on Monday,February 02, 2015, 09:31:17 AM
 :) You didn't have a T492 also, did you?
Title: Re: #460002 - Restoration
Post by: Serge on Monday,February 02, 2015, 11:16:33 AM
And while you were all posting this, I was adding big penny washers to the mount! Great minds think alike?! If the circlip will break now (which doesn't look like it would happen, there isn't any flex), the radius arm won't fall off.

Thank you all for your thoughts on this subject, I'm hoping everything will work out fine, if not, time will tell.

Serge

Edit: BDA, the owner of #460040 (going to be restored soon) here in Belgium does have a T492! As well as a Lotus Eleven, Elise S1, R340 and some other cool stuff! I'll try to make some more pictures and video next time I visit him or he comes to see me.
Title: Re: #460002 - Restoration
Post by: BDA on Monday,February 02, 2015, 12:03:48 PM
Thanks, Serge! I'd love to see them. He sounds like a lot of fun to visit! It's been a long time since I had my T492 and I'm amazed at the prices they get for S2000 cars now - but in actuality, when you consider inflation, the prices aren't that bad.
Title: Re: #460002 - Restoration
Post by: Serge on Friday,February 13, 2015, 08:09:48 AM
I've edited my footage of the fabrication of the 'competition' radius arm mounts and made this short video:


https://www.youtube.com/watch?v=0Os40ns8NiI (https://www.youtube.com/watch?v=0Os40ns8NiI)

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Friday,February 13, 2015, 09:00:51 AM
Well done, Serge!! You're going to have a really sweet car when you're done!
 :lotus:
Title: Re: #460002 - Restoration
Post by: EuropatcSPECIAL on Saturday,February 14, 2015, 04:40:43 PM
Excellent Serge, well done
Stuart
Title: Re: #460002 - Restoration
Post by: Serge on Friday,March 27, 2015, 07:58:08 AM
I found some time to upload some new photographs and write a blog post.

(http://sleurs-motorsport.com/wp-content/gallery/rear-suspension/P1120035.jpg)

It is a very long one! 62 pictures!

http://sleurs-motorsport.com/?p=1564 (http://sleurs-motorsport.com/?p=1564)

Enjoy!

Title: Re: #460002 - Restoration
Post by: BDA on Friday,March 27, 2015, 08:47:18 AM
Another great job, Serge!! I like that you used helicoils in your aluminum threads - something I wish I had done when I built my car (for the life of me, I don't know why I didn't!). It was also cool how you rebuilt your radius arm and I'm really glad you found that crack in the inner lower link bracket! I'll bet you are too!

Keep up the great work and thanks for posting the links to your pictures and videos!
Title: Re: #460002 - Restoration
Post by: blasterdad on Friday,March 27, 2015, 05:24:23 PM
Doing it right as always!
Taking the extra step to prevent future problems is never excessive, just part of doing the job correctly.
Your work is truly inspiring, & when it's completed you will have my vote for the most envied S1 on the planet !!!!
(unless you run across #0001) lol.
Title: Re: #460002 - Restoration
Post by: StrawberryCheesecake on Sunday,May 24, 2015, 02:01:24 PM
Great thread, Serge. Inspiring stuff.
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,August 02, 2015, 01:37:21 AM
Hi all,


I've been featured on Build-threads.com with my blog and video series! Check it out in the link below.

http://www.build-threads.com/build-threads/lotus-europa-barn-find-restoration/ (http://www.build-threads.com/build-threads/lotus-europa-barn-find-restoration/)

Otherwise, I've just moved house after graduating university and started my new job. I've been DIY'ing on the house for the moment, but it's slowly getting finished. One of the next jobs will be cleaning out the garage so I can get back to working on the Europa. I'll also have to find some time to upload some new video, because there's a lot to be seen!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Sunday,August 02, 2015, 10:08:16 AM
Congratulations on being featured on Build-threads, graduating, and getting into your new house!!! That's a lot of good news!  :beerchug:

I didn't realize you had the oldest S1 in existence! That's pretty cool, too!  :beerchug:
Title: Re: #460002 - Restoration
Post by: Serge on Saturday,September 05, 2015, 05:04:12 AM
https://www.youtube.com/watch?v=Y5Sp8MZmlfM (https://www.youtube.com/watch?v=Y5Sp8MZmlfM)
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,October 18, 2015, 01:26:03 PM
Uploaded another video!

This one is on the restoration of the rear suspension (apart from the rear bearing carriers, those are for the next video, to keep the length down).

https://www.youtube.com/watch?v=FLb9N0t8DJY

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Sunday,October 18, 2015, 07:19:46 PM
Another great video, Serge! I like the added touch of blocking out the radius arm so water and dirt could not get inside!
Title: Re: #460002 - Restoration
Post by: Serge on Monday,October 19, 2015, 12:59:23 AM
If you saw the amount of dirt I had to scrape out of them, you'd have done the same. It wasn't a pleasant job!
Title: Re: #460002 - Restoration
Post by: 3929R on Tuesday,October 20, 2015, 09:26:46 AM
It is great that you're both restoring this important car and video documenting the process. Well done man!
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,October 25, 2015, 02:45:55 AM


(http://sleurs-motorsport.com/wp-content/gallery/enginemounts/dynamic/P1130181.jpg-nggid03781-ngg0dyn-640x480x100-00f0w010c010r110f110r010t010.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/enginemounts/dynamic/P1130182.jpg-nggid03782-ngg0dyn-640x480x100-00f0w010c010r110f110r010t010.jpg)

(http://sleurs-motorsport.com/wp-content/gallery/enginemounts/dynamic/P1130185.jpg-nggid03783-ngg0dyn-640x480x100-00f0w010c010r110f110r010t010.jpg)

I put in a little effort yesterday to upload some photographs and write a few words about them. So there's a new blogpost, on me building the competition style engine mounts using the original mounts as a base to start from.

http://sleurs-motorsport.com/?p=1626 (http://sleurs-motorsport.com/?p=1626)
Title: Re: #460002 - Restoration
Post by: blasterdad on Sunday,October 25, 2015, 06:20:36 AM
Outstanding work & blog as always!  :welder:
Title: Re: #460002 - Restoration
Post by: Serge on Monday,October 26, 2015, 07:44:57 AM
I'm slowly getting up to speed on getting these videos out... Everything was filmed almost a year ago, but we're getting there!

New video online, restoring the rear bearing carriers:

https://youtu.be/e0VdBZLzsWQ
Title: Re: #460002 - Restoration
Post by: BDA on Monday,October 26, 2015, 08:28:38 AM
Another great video, Serge!

I used hot water to get the bearings out of the upright. This was specified in the TC workshop supplement, but I didn't see that spelled out in the S1/S2 workshop manual for some reason.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,January 04, 2016, 02:15:46 AM
Happy new year everyone!

New year, new video!

I managed to edit the video on making the poly bushed engine mounts.

https://www.youtube.com/watch?v=QdnSkwT_Fco

Next up is the poly bushed gearbox mount that I made, I'll try to share it sooner rather than later...


Serge
Title: Re: #460002 - Restoration
Post by: BDA on Monday,January 04, 2016, 06:59:01 AM
Very nicely done, Serge! I was thinking that was a lot of work for something you can buy but I see Richard sells them for over 100 pounds each so it makes sense. I can't wait to see you start assembling the car! Keep up the great work.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,January 04, 2016, 07:09:39 AM
Yes, it is quite a bit of work, but if you don't count the hours needed to build them, you are better of making them yourself. The bushes and housings aren't expensive to buy. This car is definitely built, not bought...
Title: Re: #460002 - Restoration
Post by: Chuck Nukem on Tuesday,January 05, 2016, 06:26:12 AM
Built not bought indeed!! Impressed as always!
Title: Re: #460002 - Restoration
Post by: 460384 on Monday,January 11, 2016, 07:34:25 PM
Happy new year everyone!

New year, new video!

I managed to edit the video on making the poly bushed engine mounts.

https://www.youtube.com/watch?v=QdnSkwT_Fco

Next up is the poly bushed gearbox mount that I made, I'll try to share it sooner rather than later...


Serge

Excellent work and video as always very informative.
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,January 17, 2016, 04:35:53 AM
Thank you all for the kind comments!

(http://sleurs-motorsport.com/wp-content/gallery/gearboxmount/P1130204.jpg)

I had some time to write up a post about the poly bushed gearbox mounts that I designed and built, so here it is:

http://sleurs-motorsport.com/?p=1674
Title: Re: #460002 - Restoration
Post by: Serge on Sunday,March 20, 2016, 03:43:49 PM
And of course the video that has to go along with it!

https://www.youtube.com/watch?v=MIobggnxCP8


Enjoy!

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Sunday,March 20, 2016, 06:38:44 PM
Another great video, Serge! I can't wait to see the rest of them!  :welder:
Title: Re: #460002 - Restoration
Post by: Serge on Monday,July 18, 2016, 07:42:17 AM
A couple of new videos online, written article of the driveshafts is to follow.

Removing an S1 chassis:
https://www.youtube.com/watch?v=RGojk7Vff8M (https://www.youtube.com/watch?v=RGojk7Vff8M)

Restoring driveshafts:
https://www.youtube.com/watch?v=Fnk6DBfz_Ko (https://www.youtube.com/watch?v=Fnk6DBfz_Ko)

(http://sleurs-motorsport.com/wp-content/gallery/videoseries/driveshaft.PNG)
Title: Re: #460002 - Restoration
Post by: Bainford on Monday,July 18, 2016, 08:58:47 AM
Thanks for the video. I'll watch all of it later, but it may prove helpful as I'm ripping the axels out of my Special in a couple of weeks for bearing and u-joint service. Cheers.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,July 18, 2016, 12:45:55 PM
I have a separate video coming on the installation of the stub axles in the uprights. I'll try to get it together soon.
Title: Re: #460002 - Restoration
Post by: Runningwild on Monday,July 18, 2016, 05:12:47 PM
Thanks Serge. I'll be at that point in a few weeks. Keep the videos coming. Tremendous help.
Title: Re: #460002 - Restoration
Post by: Serge on Monday,January 02, 2017, 04:35:45 AM
New video online!

In this video I'll tackle the assembly of the rear suspension including the stub axles and drive shafts.

https://www.youtube.com/watch?v=4tDs8oNti6A (https://www.youtube.com/watch?v=4tDs8oNti6A)
Title: Re: #460002 - Restoration
Post by: Certified Lotus on Monday,January 02, 2017, 05:02:27 AM
Just found your restoration videos last night and watched a number of them. Excellent work Serge! I'm really impressed by your level of work and attention to detail. Even more impressed that you seem to be working in a garage that has limited tools and equipment. Very inspiring!
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,January 03, 2017, 11:39:18 AM
Thank you for the kind words!

I have been working more and more on the Europa, but don't seem to find the time to upload any video or photographs. I'll post some quick phone-shots of some things I have been doing.

Made 2 S1 fuel tanks from scratch, refurbished the rear Carello light units with some better lenses, restored the original horn and restored 1 gauge (to test my method)

Serge
Title: Re: #460002 - Restoration
Post by: BDA on Tuesday,January 03, 2017, 12:48:33 PM
I'm watching your video now so I can't comment on it (but I'm not at all worried that I won't learn something!), but I wanted to comment on your pictures. That's really great work! The tanks look great and your restoration of your gauge and tail lights came out great! Tackling the restoration of your gauges will save you a lot of money!

Thanks for your new video and I hope your build continues to go smoothly so you'll be driving your baby soon!
Title: Re: #460002 - Restoration
Post by: jbcollier on Tuesday,January 03, 2017, 03:49:12 PM
Where's the vacuum gauge from?  They didn't come with one originally.
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,January 03, 2017, 11:03:55 PM
The vacuüm gauge is an aftermarket item that was added by a previous owner, it won't by going back in the car. It was a good gauge to check how well I could restore the instruments.
Title: Re: #460002 - Restoration
Post by: EuropaTC on Tuesday,January 03, 2017, 11:24:48 PM
Where's the vacuum gauge from?  They didn't come with one originally.
I bet it's aftermarket John, they were very popular in the 60s/70s over here and something young lads (me ! ) usually fitted in every car they had.  My dad even fitted one to his 3-wheel car at the time !  The one Serge shows is very reminiscent of what I had then. 
Brian

Edit to add - woops, I must check for posts between me starting to write and eventually pressing "send".   
Title: Re: #460002 - Restoration
Post by: Serge on Monday,May 29, 2017, 05:07:56 AM
Trying to get some videos up. Been trying to work on the car more, so need to get these videos up. These have been filmed more than a year ago!

https://youtu.be/QYB3KBvy3SI

Making an aluminium coolant swirl pot!

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,October 18, 2017, 12:03:37 PM
Another video uploaded!

Next video to edit is the first one that I filmed with my new camera (more than 2 years ago!). I have a very large backlog of footage that I need to edit and upload, but were are getting there!

Serge

https://www.youtube.com/watch?v=fi_UhwxRnMs
Title: Re: #460002 - Restoration
Post by: 4129R on Wednesday,October 18, 2017, 12:15:18 PM
Where's the vacuum gauge from?  They didn't come with one originally.
Always remember to fit the vacuum gauge on the wife's side of the car.

It makes them feel at home.

I never got around to fitting one in any 70's car I owned, as I didn't really know what it was supposed to do.

Self cleaning car?
Title: Re: #460002 - Restoration
Post by: BDA on Wednesday,October 18, 2017, 12:36:08 PM
Quote
Another video uploaded!

Another great video, Serge! I would make a few minor points:

As a rule, I would install shims dry so the gap they are keeping isn't changed.

It is also important to get the right preload on the inner tie rod end assembly. If the tie rod assy. is too loose, it can make the car a bit unstable. (ask me how I know) IIRC correctly, it is supposed to take about seven pounds to move the tie rod.

Those are minor points though. When you're done - if you keep editing them - you will have a great video guide to building an S1.
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,October 18, 2017, 12:40:16 PM
I tested the preload with the weights, but could not find any video of it, not sure If I did record it.

T
Title: Re: #460002 - Restoration
Post by: jbcollier on Wednesday,October 18, 2017, 02:10:20 PM
For steering boxes I use semi-fluid grease (aka: steering box lube).  It's a bit more on the liquid side and flows around inside better as the rack goes from side to side.  Don't have any?  Dilute the chassis grease with gear oil to make it more fluid.  Rebuilt already with chassis grease?  Add gear oil through the lube hole covered by the non-pinion side mount.
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,October 24, 2017, 02:16:20 PM
Thanks for the tip, John. I'll dilute the grease with some gear oil.


I'm trying to get this back-log of videos on the internet. Short video this week,
replacing the heater tubes with aluminium. I haven't put a bead on the ends just yet, Might still weld a small bead around them to help keep the hose on.

Serge

https://www.youtube.com/watch?v=tTrGy3ZBydU (https://www.youtube.com/watch?v=tTrGy3ZBydU)


Title: Re: #460002 - Restoration
Post by: jbcollier on Tuesday,October 24, 2017, 02:30:30 PM
A couple of rivets at each end works just like a bead and is easily done in situ.
Title: Re: #460002 - Restoration
Post by: Serge on Wednesday,October 25, 2017, 02:59:22 PM
I know of the rivet trick, but am a bit worried that he inner part of the rivet would impede flow of the already small inner diameter tubing. Considering what I hear about the lack of heater power, I am not sure if I want to hinder it any more. Not sure if it would actually need a bead, but would hate to figure it out the hard way...

Serge
Title: Re: #460002 - Restoration
Post by: jbcollier on Wednesday,October 25, 2017, 03:36:11 PM
Use shallow rivets and then crush them further with pliers.  Mine gives pretty good heat given that I don't run it in below freezing weather.  I use a 160° thermostat as well.
Title: Re: #460002 - Restoration
Post by: lotusfanatic on Wednesday,October 25, 2017, 11:26:46 PM
I guess fitting solid rivets would be the best method but almost impossible to install?
My only concern, if using blind rivets, is the possibility of the internal shank/head coming adrift and ending up drifting around in the coolant system?

Mark
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,October 26, 2017, 01:30:55 AM
I can TIG weld aluminium, so I'll quickly weld a few spots or bead around the end of the tubing. Should be fine after that.

Serge
Title: Re: #460002 - Restoration
Post by: lotusfanatic on Thursday,October 26, 2017, 05:03:34 AM
that would seem the best way, if you’ve got access?

Mark
Title: Re: #460002 - Restoration
Post by: Serge on Thursday,October 26, 2017, 06:12:07 AM
The tubing is not permantly attached to my chassis, so that won't be a problem.

Serge
Title: Re: #460002 - Restoration
Post by: Serge on Tuesday,November 28, 2017, 11:55:21 AM
Video on how I replaced the old rusty coolant pipes with new aluminium tubing.


https://www.youtube.com/watch?v=wRCQzEdPb44
Title: Re: #460002 - Restoration
Post by: lotusfanatic on Wednesday,November 29, 2017, 12:19:18 AM
Thanks Serge!
Title: Re: #460002 - Restoration
Post by: Europaforever on Friday,January 12, 2018, 01:40:26 PM
 :beerchug: