Lotus Carlton C36GET bottom end rebuild [Archive] - Performance Nova Group

Keif

15-07-09, 07:01 PM

I had not been able to get on here for a bit due to Virgin Media being sh!t.

While i was away, i've been busy.
I realise this isn't Nova based, but i thought you guys and girls would be interested.

(I'll update it daily even tho it's already been done)

In March this year my Lotus Carlton failed it's MOT on rust, it had a small hole in the rear of the nearside sill. No biggy as my mates a welder, but on the journey back home i broke down.

Thankfully, only three streets away, and my neighbour was on his way back home, so he towed me home.

After checking things out, it was clear the damaged crank damper was the result of the main problem.

Which is.....the rear bearing shells fecked. The crank moves back when the clutch is pressed, pulling all the pulleys etc back towards the block.

One full bottom end rebuild coming up. :eek:

Thankfully, all bits required are not Lotus Carlton specific bits. Assuming the cranks not damaged.

So, after a week of night's i decided i'd get up early and get out and start to strip some bits the C36GET.

The plan is to tinker during this week, and hopefully lift it out next weekend.

As i'd removed a few bits when diagnosing the problem, i had to push the LC out the garage.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1429.jpg

Jack the car up and drain the coolant (i ignored the disconnect battery bit, as i want to keep it locked :D)

While the coolant was being collected, i decided to label up a few coolant pipes. (I didn't need to do this, but just to be safe)

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1430.jpg

All jubilee clips undone and all top coolant pipes were quickly removed.

Airbox uncliped and removed .
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1432.jpg

With the pipe feeds to the turbos removed i had to take a few arty pictures.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1434.jpg

New favorite pic. :D
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1435.jpg

After removing the turbo heatshield, the Chargecooler was next.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1433.jpg

The removed bits (now residing in the cars boot)
http://photos-a-0.ak.fbcdn.net/hphotos-ak-snc1/hs013.snc1/4480_111308894368_655244368_2813648_2087320_n.jpg (http://photos-a-0.ak.fbcdn.net/hphotos-ak-snc1/hs013.snc1/4480_111308894368_655244368_2813648_2087320_n.jpg)

Not a huge haul, but the offside of the engine is rather stripped.

to be continued......

burgo

15-07-09, 07:31 PM

your a braver man than me. take lots and lots of pics

Mike

15-07-09, 07:36 PM

Yay, a proper engine :) will keep my eyes on this thread :)

Joe Richardson

15-07-09, 07:45 PM

we need lots and lots of pics of this,keep us informed:thumb:

keep up the good work:)

mowgli

15-07-09, 08:00 PM

isn't the bottom end a stroked 3000gsi one??

Keif

15-07-09, 08:17 PM

isn't the bottom end a stroked 3000gsi one??

Yep, longer stroke adding an extra 0.1l per cylinder.

mowgli

15-07-09, 09:21 PM

Nobby

15-07-09, 10:18 PM

keep the pics coming :D

General Baxter

15-07-09, 10:23 PM

i would so get that im my saloon :p

mowgli

15-07-09, 10:28 PM

i would so get that im my saloon :p
what, across the back seat???

General Baxter

15-07-09, 10:28 PM

in the front

mowgli

15-07-09, 10:33 PM

cough cough... room for feet & dashboard cough cough

AlexW

15-07-09, 10:37 PM

cough cough... room for feet & dashboard cough cough

There not needed lol

Keep us updated :)

Rickyb

16-07-09, 08:22 AM

that is the boll#ox

CorsaBBoomer

16-07-09, 09:37 AM

Seen this engine in a Chevette once... Guy didn't get insurance since it was too much for the car lol

Nice project mate :thumb:

Sloth

16-07-09, 09:54 AM

sorry for the o.t but does anyone remember the white corsa b with it in?

Kev Turbo

16-07-09, 10:44 AM

sorry for the o.t but does anyone remember the white corsa b with it in?

What that photoshop that floated around for years!lol

draper

16-07-09, 10:48 AM

about time lol

let me know when its ready for firing up and ill pop round for a cuppa ;)

Plug

16-07-09, 11:08 AM

i would so get that im my saloon :p

i dare you would be a good project

Keif

16-07-09, 12:36 PM

are the shells std gm or something weird from a renault (like most other lotus stuff)?????

I often wondered just how much input was from lotus, as they were owned by gm at the time, or if it was a bit of a marketing thing... I know it has a corvette gearbox, but how much stuff has lotus stasmped on it??

The engine is basically a Vauxhall 3.0l 24v block/head with alot of Lotus magic spread all over it.

The car was originally a Carlton GSi before going to Hethel, so alot is Vauxhall but the engine, gearbox and suspension has been Lotusised.

The gearbox is a ZF Friedrichshafen AG unit which was also used in the Corvette ZR1.

Keif

16-07-09, 12:49 PM

I assume you all missed this in my first post.

(I'll update it daily even tho it's already been done)

Pics from 8th June.

The area to concentrate was.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1538.jpg
The Inlet Manifold (and surrounding area)

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1539.jpg
Battery out, Coil Pack disconnected, next.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1540.jpg

Then the main fuel feeds disconnected, throttle bodies off......et voila.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1541.jpg

I didn't need to remove the Inlet manifold, but i had the rocker cover and charge cooler powder coated last year and want to get it powder coated to match.

to be continued......

skidmarkz

16-07-09, 12:59 PM

jebus that is one busy engine bay, take loooooooads of pics dude lol

that washer bottle/Tank is nearly as big as a c20xe lol

Keif

17-07-09, 01:51 PM

The next small session update.

The last two coolant pipes marked up and disconnected.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1542.jpg

Servo pump undone. reservior undone and moved out of the way.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1543.jpg

Wiring loom harness removed.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1545.jpg

Engine Loom all disconnected and tucked out the way.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1546.jpg

Southie

17-07-09, 01:55 PM

My words I don't envy you getting all that back together. :eek:

I would love a go in one of these. ;) :d

Keif

17-07-09, 01:57 PM

As that's a little update........

The day it came out!

I was helpped by two mates, very much needed and appreciated help.

The target.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1559.jpg

Harvey looking to see what stage it's at.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1561.jpg

While Ste hides. :D
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1562.jpg

Then wondered why i was still taking pics and not undoing bolts.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1564.jpg

Bonnet off.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1569.jpg

Engine mountings unbolted, and we could only lift is this far.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1572.jpg

The Bell Housing wouldn't part from the block.
So a phonecall needed to a fellow LC owner. The only way to get the engine out is to take the gearbox out first.

So exhaust off
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1571.jpg

Harvey showing you all my "flaps"
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1570.jpg

Then out came the huge ZF gearbox.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1568.jpg

Then hey presto, out it popped.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1577.jpg

Quite surprised om how big the flywheel clutch assembly is.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1573.jpg

burgo

17-07-09, 08:13 PM

:eek: size of that fooking flywheel!!!!!

whats the flaps for aswell

Keif

17-07-09, 08:29 PM

The flaps are vacuum controlled. they're shut when the engines started to warm the cats up, then they open up as per normal flow.

I think i'll be taking them out the system in the future.

Spudly

17-07-09, 08:30 PM

WOW........................:eek:

stupot89

17-07-09, 09:03 PM

that is one hell of a flywheel as said i dont envey you puttin it back together

mowgli

17-07-09, 10:13 PM

i assume the flywheel is so huge because its the easiest way to get the spacing right to get the box to fit

mowgli

17-07-09, 10:14 PM

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1570.jpg
http://www.askachola.com/img/short-circuit-2-cholo-robot.jpg

teamdangerous

17-07-09, 11:39 PM

You can take the bottom end out to 4L easily - Irmscher used to do a kit with a steel crank & rods, and pistons. I've seen some pics of a German Lotus Omega which broke it's block after being wound up to over 500bhp. The owner then made some girdles to reduce the amount of flex in the block.

I'd still love a Lotus Carlton, but if I had one, I'd wreck it!!

I very nearly fitted a turbo kit to my 3.0L Senator (12v version) - but the kit was designed for a Carlton, and would have fouled the Senator's ABS unit. I didn't fancy re-working it all, so gave it back (I was given the kit!!).

Will F

18-07-09, 12:07 AM

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1570.jpg
http://www.askachola.com/img/short-circuit-2-cholo-robot.jpg

Sorry, but that is funny as!!!!

lol lol lol

dj_wudgey

18-07-09, 11:22 AM

keep it up dude!! the car is very nice matey!!

Joe Richardson

18-07-09, 03:26 PM

Good work keith :thumb:

These cars were so advanced for the time,lovely car mate:)

Keif

18-07-09, 08:11 PM

Sorry, but that is funny as!!!!

lol lol lol

lol Quality.

Keif

18-07-09, 08:14 PM

So the next step was to take the clutch and flywheel off ready for it to be hung on the engine stand.

Which was done on "Day" 5, and spun over.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1600.jpg

Then the sump was undone and removed.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1606.jpg

While it's as this stage, i'm going to replace the Big End shells as a matter of course. (seems daft not to)
So i need to see what state they're in, and if the cranks damaged.
So end cap undone.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1609.jpg

and the shell removed.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1610.jpg

Nice shiney, UNDAMAGED crank.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1611.jpg

Time to find the problem.
Rear crank bearing cap undone and removed.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1613.jpg

The problem was quickly obvious.
The bearing shell should be the same thickness both sides, mines burnt and worn on the crank side.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1614.jpg

Which allows it to move (about 2mm)
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1615.jpg
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1616.jpg

I need to make a call tomorow and find out costs now......(GULP!!!!)

*Adz*

18-07-09, 08:24 PM

wow... some really good project here... im subscribing to this! keep up tthe good work... love these cars!

djbrowney

18-07-09, 09:08 PM

awsome work, rather you than me but would still love a play in one lol

mikey14sr

18-07-09, 09:18 PM

Looks like you've got to it before it's disappeared completely though, so there shouldn't be much if any damage to the crank I'd have thought.

Can't believe the size of that flywheel, must weigh as much as the block!

stupot89

18-07-09, 10:06 PM

at least the crank is ok wouldnt want to think how much a regrind or a new/second hand one would have been

tomo06tomo

18-07-09, 10:33 PM

hey Mate these are one lovly car ive had a go in one i no grage who has one from new and he took me down the a63 in it and i was fast and i mean fast my dad use two drive a bmw M5 440bhp and that was fast but the calton jist felt as fast the bmw was a 52 plate one not the new one lol but yeah good look mate one hell car yew got there :D

Keif

19-07-09, 12:58 PM

Another update.

When i ordered the Shells and Bearings, i was nicely surprised on the price, I had change out of £200. :)

I also enquired about the uprated timing chains as the Vauxhall ones it had fitted are crap. :D

As i couldn't do much on the internals of the engine at the moment. I started sprucing up the block.

Inlet side.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1619.jpg

Painted
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1621.jpg

Exhaust side of the engine.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1622.jpg

Painted
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1630.jpg

Top timing plate and primary cover off.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1629.jpg

I was one bolt away (i think) from being able to take the timing chain off the crank gear.

Then it's the crank unbolted and out. I didn't do that until the replacements arrived.

At this point I found some major rust in the top of the front nearside chassis leg once the engine was removed. I cut out the dead metal, and prepare it for repair. I found a good welder, who was prepared to come to my house and do the work on my drive. We also sorted out the rot it failed it's MOT on.

Keif

20-07-09, 10:35 PM

Induction Manifold time.

I took this off before lifting the engine out, so i could get it powder coated to match the Rocker Cover and Chargecooler (I had these done last year)

Taken out.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01600.jpg

Stripped
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01604.jpg

Powdercoated
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01615.jpg

Then the ancileries refitted. (Shows the colour better)
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1631.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1632.jpg

It will be bolted on before the engine goes back in this hole.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01616.jpg

burgo

21-07-09, 12:38 AM

its nice to see something different and this is certainly that lol

Jonlem

21-07-09, 01:52 AM

Awesome thread, tbh just because its a LC that doesn't mean its harder than any other engine to put together !

Great progress though, that crank looks like a proper steel one, are the rods H beams or anything like that ?

Quite interested to see exactly what they put in the engines

Joe Richardson

26-07-09, 10:38 AM

Any more progress pics on this:thumb:

Ben

26-07-09, 11:43 AM

An excellent read, look forward to the next installment.

As James said its only an engine with nuts and bolts but you are doing a nice job.

People are just scared due to the rareity and value of these things.

dj_wudgey

26-07-09, 11:49 AM

this is a excellent thread!! as ben said most people wouldent even try work on these as they are so rare!! but much respect for getting stuck in!!

dan16v

26-07-09, 04:56 PM

Good read this! intresting to see what one looks like in bits!

Keif

29-07-09, 09:35 PM

A bit more reading.......

Time for a further update.

Decided it was time to take the crank out.

So.....
Big end bolts (note middle bearing shell cap is already undone)
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01625.jpg

Then onto the rest of the main bearing caps
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01626.jpg

Timing Chain off the Crank Sprocket. (Guide and tensioner rail removed)
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01627.jpg

Then lift the crank out.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01629.jpg
(Junior Hacksaw for scale)

Then on to a major set back.
I noticed this when it was in the block, but my Dad questioned if it was wear or not.

The Rear Bearing Journal has worn about 1mm into the side of the journal.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSC01632.jpg

So i either need to get this repaired or source a replacement.

Looked at the repair route, but i'm not happy getting it metal sprayed and re machined.

So, Dave Franczak (see http://www.lc890g.co.uk/) to the rescue for a replacement. It's more than doubled the total cost of the whole job, but needs must and i'll have peace of mind.

Ben

29-07-09, 10:21 PM

yes a set back but as you said rather have it right first time round than have to redo the work another year down the line,

Johnny A

29-07-09, 10:33 PM

Keif

14-08-09, 08:11 AM

I take it your a member of ABS? Might be a good idea if not as i'd recommend new uprated timing chains and guides off some of the site members. The uprated chains are much beefier than the GM originals (even the 'uprated' GM ones). I replaced both chains, all three guides and the bottom sprocket when I rebuilt my 3.0 24v Senator.
;)

I also enquired about the uprated timing chains as the Vauxhall ones it had fitted are crap. :d

A Tuesday Morning long agoi had a small, light package arrive.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1724.jpg
Kitchen for scale

In that box were these.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1725.jpg
Oh and a replacement crank.

So in the afternoon the old shells and bearings were removed.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1727.jpg

Spot the difference.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1728.jpg

All top half bearings and shells in place.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1730.jpg

That looks better.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1731.jpg

So does that (not the best pic, sorry)
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1733.jpg

The replacement crank cleaned and in place.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1734.jpg
Then the bearings, shells and caps installed and torqued up.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1735.jpg

The sump was lightly bolted in and the engine spun over. To replace the timing chains the Rocker cover needs to come off.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1737.jpg

The new uprated chains fitted, but NOT tensioned as i needed to pick up a replacment timing chain guide.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1738.jpg

I must keep updating this.

Johnny A

14-08-09, 10:50 PM

Yep they are the chains all right! So thick they look they belong on a motorbike lol

craig green

14-08-09, 11:09 PM

Awesome read. First time I've looked in.

Gorgeous car too, she looks mint.

Keif

15-08-09, 08:31 AM

The next instalment.

As the Rocker cover off it'd be rude not to take a few pics.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1742.jpg
At this point the uprated chains were on, timed, tensioned and checked.

Arty pic
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1743.jpg
(Note, Cam 1 at raised point)

I then fitted a spare 3.0 24v rocker cover i have, as i don't want to damage the Lotus one refitting the engine to the car.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1744.jpg
(It's lying it's 0.6 bigger than that)

The whole thing was spun over again, and the cleaner sump sealed and fitted.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1746.jpg

At this point all coolant and oil pipes/feeds were reconnected.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1748.jpg
Note Timing Covers now fitted
(I'm tempted to paint the four "valves" on the top timing cover the same as the rocker cover, chargecooler and inlet manifold - Your thoughts)

Another spin over.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1750.jpg

The Fuel rail now slid onto the studs. After this i've just perched the inlet manifold inplace.

Ben

15-08-09, 02:16 PM

I think painting those 4 valves would tie it all in together and you wont get a better chance to do it.

Coming back together nicely!

Keif

25-07-10, 04:40 PM

Originally posted 04-07-2009

Update time.

I didnt get chance to post these yesterday.

I ordered a new Oil Filter, the one that was on the car had only done about 12miles, but for the sake of £9, it wasn't worth refitting it.

I also picked up some clutch fluid, powersteering fluid and popped into Vauxhall and got the correct front crank Seal.

So i bolted on the engine mounts, tightened the induction manifold studs and fitted the front crank seal before removing the engine from the stand and onto the crane.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1755.jpg

I then fitted the rear crank seal, the flywheel and clutch assembly.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1756.jpg

All ready to put it back in the car.

Keif

25-07-10, 04:41 PM

Originally posted 04-07-2009

Today's doings.

I open the garage at 8am and the morning sun was already encouraging us.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1757.jpg

The lump ready was dragged out of it home for nearly a month.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1758.jpg

Then dropped down, and relifted at the required angle to get it in the engine bay.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1759.jpg

It's a rather tight fit.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1760.jpg

The engine was lowered so we could get to the flywheel/clutch and fit the Clutch pin/fork and bellhousing.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1766.jpg

Then we had the task of getting the huge gearbox to line up and locate the splines.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1767.jpg
This was probably the hardest bit all day.

Once the Bellhousing and gearbox were all bolted together the whole lot was lowered onto the engine mounts.
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1772.jpg

Hey presto, IT'S IN!
http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/Engine/DSCF1773.jpg

We then reconnected the prop, fitted the exhaust system.

It's just needs plumbing back in now!

Keif

25-07-10, 04:42 PM

Originally posted on 08-07-2009

Well it was MOTed today and it passed.....but.

Let me explain.

Harvey and I had an epic afternoon evening yesterday. I do have pics, but i've not uploaded them yet.

At about 21.15, i turned the key a couple of times to get the fuel and it burst into life.

Left it running to try and get rid of most of the oil, and so that the Thermostat opened.

All seemed well and we put it to bed ready for it's big day today.

So this morning i checked the coolant, oil and power steering fluid fitted the suspension pump and set off.

Straight away it was clear i'd not got any boost, but i limped to the MOT.

While i was waiting until the ramp was clear i refitted the gear lever hatch cover and the centre console.

It has a few advisories, nothing i didn't already know about, when told about the low front brake pads i even produced a replacement set ready to fit in the calipers.

However, i have a clutch issue, i'm not 100% if its just a bleed problem or worse, but i ended the afternoon being towed back home by a very nice RAC man.

LC clutches are a nightmare to bleed, the bleed nipple is on the SIDE of the slave cylinder, so you can bleed it and get no air bubbles and it still have air in the system as it's all above the nipple.

There are also signs of oil from the bell housing, not sure if it's all over the clutch or not, it's going to be a sump off job before anything else is investigated.

So unfortunatley the LC won't be at Billing, i'm gutted but more upset at the new damage on the side of the Astra i found today.

I need to thank a few people.
The work the Harvey and Ste_Goffy have put in to help has been immense. Most evenings (and some afternoons) over the last few weeks have been put aside to help and some nights we've relied on torch light before we've called it a day.

Also half of Harveys tools/lifting equipment seems to have found it's way into my garage.

Dave Franczak, i keep ringing him for help, advice or bits. He's always been very helpful and i'd have thought i'd have annoyed him by now.

Also Zoe, she's been sat on her own most evenings.

So, as the first chapter closes, a new one opens.

Keif

25-07-10, 04:44 PM

Originally posted 27-09-2009

It's back and it feels Sooo good.

Yesterday was quite a big day for me.

I'll let the pictures do the talking.

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261017.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261019.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261020.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261023.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261024.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261025.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261026.jpg

http://i71.photobucket.com/albums/i124/Keif_1974/Cars/Lotus%20Carlton/P9261027.jpg

It's been almost a year, hours of tears and stress. Worth all that yesterday.

Not 100% happy on the rear end height, so i'll be looking at that this week.

It'll get a wash, polish and wax this week.

See HERE (http://www.astraownersclub.com/vb/showthread.php?t=202296) for the reason it was off the road.

Huge Thanks to
Harvey and Amanda
Ste Goffy and Karen &
Zoe