Lotus Europa Community

Below is another stolen pic of the method I used - washers cut from a drywall sanding sheet.
My impression is that using a finer grit is better. The previous course grit abrasive washers made from grinder discs just seemed to crush the abrasive chips.

The diamond cut-off disc idea sounds perhaps better, I reckon. The trick might be finding ones with the plain steel centre section which can be drilled out easily.

I doubt there's anything that will stop the hinge pin rotating in the bobbin.
I think it was Brian? (EuropaTC) who showed a method of constraining relative movement of the stock single piece pin.
I'm not familiar with the Banks hinges apart from pictures but they appear to actually enforce rotation of the pin(s). Is that correct?

The upper ball joints on my S2 appear new, a lot of work was done just before it went into storage.
But the boots have rotted away over time.
Somewhere I saw a suggestion to use Energy Suspension 9.13105G Tie-Rod end boots.
They are certainly cheap enough and probably much more durable than rubber.
But I have to rate them as a Fail.
They have no return lip or spring wire to hold them in place at the wide end.
Under articulation the wide end will not stay in place to form a waterproof seal.

Now thinking I will just buy new BJ's.
So what brand is best quality now?
A part number and source would be even better.
Small simple part so hoping not to have to order from the UK.

Maybe some course sandpaper might be helpful.

 I have Banks hinges but didn't use washers. Just the brass nuts on the doors. I too wasn't sure if I was missing something. I don't like the brass rotating in the aluminum bobbing. I thought maybe the washers would force the hinge to rotate inside instead.

I used diamond blades (wet tile saw) everyday for 30 years. I can confirm diamonds cut through anything.

You and others have mentioned that. So at first I assembled the hinges with no abrasive washers. Still used the brass washers that came with the hinges of course. But I could not successfully adjust the doors. Either the hinge was bolted down tight enough to not move at all, or it slid around uncontrollably. I couldn't find a middle ground. Maybe it has to do with the slickness of the clear coat I used. Would it have worked if bearing against the metal of the door bobbins? I even roughed up the brass washers with 36 grit sand paper. It didn't work until I used the abrasive washers, and then it did. That's only my experience. Obviously it can work without the abrasive washers too.