S1 Type 49 Elise Refresh

[Badger02]

On 24/01/2024 at 20:08, Lithopsian said:

People have done lots of things.  Perhaps the simplest is just to add the plastic spacers from the S2.  The hinge will still be worn, but shouldn't get much worse.

I've seen the hinge built up in two different ways.  No doubt there are more.  You can add metal to the worn area and build it back up to the original level, but realistically you need the hinge off and some fairly specialised welding equipment.  Not sure how well something like a metal epoxy would last.  Adding the plastic spacer to your nice new hinge would be a good idea anyway.  Maybe even more fancy is to ream out and fill the gap with a harder metal rod.  Seloc is the place for ideas, lots of people have attacked this issue.

There have also been at least two different designs for replacements on the spring.  One of them had rollers that sat on the unworn part of the hinge either side of the groove.

 

Thanks.

Regarding the plastic spacers, do you mean part 13 ?

[Lithopsian]

No, 13 is the spring itself.  You want 26, part number A116B0418F.  Fits between the spring and the hinge surface.  Should be pennies.  Plus a big delivery charge!  Then maybe some JB-Weld so it has a nice surface to press on

[Badger02]

17 hours ago, Lithopsian said:

No, 13 is the spring itself.  You want 26, part number A116B0418F.  Fits between the spring and the hinge surface.  Should be pennies.  Plus a big delivery charge!  Then maybe some JB-Weld so it has a nice surface to press on

Thanks

[Badger02]

1st caliper I painted a few weeks ago is on the left. 2nd caliper I painted this morning on right. Spent more time on the prep and applied more coats on the 2nd one. Definitely better I'd say

[Badger02]

I didn't take the connector pipe of before painting as I remember on the 1st caliper it was quite easy to get it out of shape when removing/refitting. I'll remove the paint of the pipe.

[Badger02]

Damper bracket resprayed and this time correct torque applied to the bolts

[Badger02]

And so, 2 months more or less since I started my 1st ever S1 Elise refresh, the 1st wishbone is back in. Also fitting new ball joints, track rod ends, drop links and wishbone bushes throughout. Pretty happy with how it's turned out so far, still a fair bit to go though (in the photo the wishbone bolts are in the wrong way round, I've since turned them around).

[Badger02]

Top drivers wishbone and steering arm installed 

[Badger02]

A tip, to be able to tighten the nuts that connect the BJ and TRE to the steering arm, you need to get the bolts to bite into the tapered holes in the steering arm otherwise the bolts/nuts just spin. This is what I did and worked.

[Badger02]

Thought I'd share the list of non standard tools I've had to use so far.

Ball joint removal/install tool from elise parts.

Wishbone bush removal/install tool from elise parts.

Long straight allen sockets to access the top allen bolt on the ARB, bought from ebay.

Dremel tool, a must to remove the various seized mild steel fasteners lotus originally used.

Will add any as I think of, the rest are just socket set, spanner set, torque wrench etc.

 

[MG4Lotus]

Don't forget your lump hammer. Shows that you definitely mean business. 😁

[Badger02]

1 hour ago, MG4Lotus said:

Don't forget your lump hammer. Shows that you definitely mean business. 😁

That's a standard garage tool !

[Badger02]

When pressing the ball joints into the wishbones, make sure you pay attention that the rubber dirt cover doesn't snag otherwise you could end up damaging the cover, like I did

[Badger02]

Painted a brake disc cover today 

[Badger02]

Cleaned up the passenger wishbone connection area, little bit of corrosion but nothing I'm going to lose sleep over