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  Topic Review (Newest First)
08-30-2019 07:06 AM
addertooth All of these photos of the car... but not one of what the truck driver's nose looked like afterwards. I am impressed at how many Lotus owners have truly mastered the art of counting to ten.
07-20-2019 08:08 AM
Jaguar Front clam is getting painted, will update when it is complete and ready to be mounted.
07-20-2019 08:00 AM
Jaguar New windshield install in the beginning of June, first time the car was out of the garage in a year.
07-20-2019 07:56 AM
Jaguar Everything then took a long hiatus until about March. I received a new windshield, new shroud, and new ProAlloy radiator/condenser. After trying to remember what I was actually doing 2 months prior, I mounted the radiator, condenser, and fans together loosely, mounted that all to the inside of the shroud, and dropped the whole thing onto the front of the car. Tightened everything up after doing some slight alignments. I believe it was much easier to do it that way then putting them in piece by piece. Reinstalled the HVAC box/blower motor. New hoses for both the heater core and the radiator.

Important note: Once you install the HVAC box, for the love of your own sanity, put rags/towels anywhere you could drop small items in or around the HVAC box. I dropped one of the metal plates for the AC expansion valve and it fell down flat partially under the HVAC box, and I nearly had an aneurysm. Luckily the plate was steel and I fished it out with a magnet, but you do not want to be performing neurosurgery to get get small parts.

I reinstalled some AC tubing. I got new o-rings from Cold Hose, they had a nice #6-#12 variety pack. Always nice to have extra o-rings in case you drop one. Make sure you use the correct AC oil, and lube up the threads and o-rings prior to reassembly. Also, get a new receiver drier and make sure to install that last in the AC system.
07-20-2019 07:23 AM
Jaguar Since the blower motor resistor pack is known to die, I replaced it. It was working fine, but no sense it putting the whole thing back together and then having it blow up. A big thank you to rob13572468 for this thread on a DIY pack:
https://www.lotustalk.com/forums/f31...acement-78524/
I made a new one with the recommended resistors and used some thermal tape and screws to fix it to an aluminum heat sink of amazon. Before mounting it, I tested it to ensure I had all speeds working, and it was great. I 3-D printed a small panel to cover up the hole in the blower motor where the pack will no longer be residing.
Did some additional clean up with the air ducting, lubed up any joints, and put some HVAC tape to keep everything as air tight as possible.
07-20-2019 07:11 AM
Jaguar After that was removed, I took our the AC/heater core, which involved more heater hose removal, AC piping removal, receiver dryer removal, wire unplugging, and a aluminum bracket that holds the core in. After that, unclip the blower motor, say the correct string of curses, and put the HVAC core out. In actuality, it wasn't too difficult to get it out. This thread has some nice step by step pics (shoutout to exigegus for posting it):
https://www.lotustalk.com/forums/f31...ac-box-397449/
Under the blower was a mess, even with the 4 holes drilled in for drainage, so I cleaned that all up.
07-20-2019 07:10 AM
Jaguar
Long overdue update

Well, the birth of a first child really gets in the way of a speedy repair project...over a year after the hit, I am finally nearing the end of this project. It also took a few months to get all the parts. On to the work...

In December I removed the radiator, condenser, fans, oil cooler (only have 1), and radiator shroud. This involved removing the front under tray to allow access to the radiator hoses. I disconnected and removed the radiator hoses, oil cooler hoses, and wiring bundle that wraps from the passenger side all the way around to the driver side headlight. The most annoying part was the AC piping to the condenser since the lines are delicate. The correct 6 point flare nut wrenches are the way to go for this work. Remember to cap your AC lines to prevent dirt and humidity from entering the system. Removing a bunch of other small bolts allowed me to finally remove the damaged shroud.
10-12-2018 06:18 PM
Corvus13 This happened...

https://www.lotustalk.com/forums/f3/...y-ever-324193/


Corvus
10-09-2018 04:07 PM
Jaguar So while I'm working on the front end, I will replace the blower motor resistor pack and may install the AC thermostat service kit (is this kit really necessary?). With the radiator out to replace it and the shroud, I'll also do the coolant thermostat since the fluid will be drained. With the oil lines disconnected, might as well pull the valve cover and check the cams and the lifter bolts since I'll have to do an oil change shortly after.

Any other critical maintenance or things to look at while I'm tearing down parts of the car?
10-04-2018 05:31 AM
Jaguar Yesterday I got the car up on a U-haul auto trailer (much easier with no front clam) and brought it over to William Thomas Roadsters in Frenchtown, NJ. For anyone in the PA/NJ/NY area, Bill has a great shop and is extremely knowledgeable. He was kind enough to evaluate the front end, and as many of you suspected, the front crash structure is not compromised. Bill gave me sources for some parts to get pricing/availability, so I am working up a list of things to do while I'm tearing down the front end. I'll post it shortly, maybe you guys can give me feedback on any other good projects to tackle while it's apart.


Quote:
Originally Posted by Corvus13 View Post
Sorry to see that happened to your car, but I applaud you for pushing on with a potential rebuild. You can bring her back, especially since it looks like the crash structure is ok. Take your time and rely on the Lotus community. The guys and gals on this board are a great resource for both knowledge and parts. It's been almost four years since mine got wiped out in what I like to refer to as "the garage incident". I rebuilt and have never regretted it, not even for an instant.Corvus
Thanks! I enjoy taking things apart to see how they work, and doing it myself when feasible to save some money. I think this will be a good fall/winter project. It's not a rush, and like you said, there is a wealth of knowledge and super friendly group of people on this site, so I'm sure it will go well. What happened to yours?

Quote:
Originally Posted by Roundabout View Post
Great to see that your crash structure was not damaged. I do have a spare radiator shroud (and a crash structure) if you need it. You're so far away that you are probably better off finding one closer to you, but if you can't find one, PM me.
Thanks! If I can't find one I'll be in touch.
10-02-2018 01:15 PM
Roundabout Great to see that your crash structure was not damaged. I do have a spare radiator shroud (and a crash structure) if you need it. You're so far away that you are probably better off finding one closer to you, but if you can't find one, PM me.
10-01-2018 09:19 AM
Corvus13 Sorry to see that happened to your car, but I applaud you for pushing on with a potential rebuild. You can bring her back, especially since it looks like the crash structure is ok. Take your time and rely on the Lotus community. The guys and gals on this board are a great resource for both knowledge and parts. It's been almost four years since mine got wiped out in what I like to refer to as "the garage incident". I rebuilt and have never regretted it, not even for an instant.

Corvus
10-01-2018 09:12 AM
Jaguar
Quote:
Originally Posted by Crazy05 View Post
What kind of tires are those? How do you like them?
They are BF Goodrich g-Force T/A KDW-2 tires. They were on the car when I bought it, and I've replaced them when the first set ran out. I like them, but I've never had anything else so I don't have much to compare them to. I believe they were discontinued so I'm gonna have to try something else next time.
10-01-2018 04:51 AM
Crazy05 What kind of tires are those? How do you like them?
09-29-2018 05:57 PM
Motard Dang, That's rough for sure. I have had unscheduled down times with my car in exploded view. What Zakria said, even when your in the weeds, just muddle through.

Sorry, someone else's lack of attention to detail ( reality) has caused you so much turmoil. Certainly not worth whatever is left over $ is much of a consolation prize. Most likely you will end up using it to fix or upgrade this and that whilst your in there. I always felt that improving as much as I can when fixing the necessary makes me at least feel like the net of unfortunate events a positive. Of course that is when it is all back together. I know that from my own experiences. May the Lotus Gods smile upon thy countenance next spring!
09-29-2018 02:04 PM
zakria Don't worry, you will fix your car, just be patients and you will get the car back on the road.

Mine took 3 months to work on it

however at the end of the project felt more in love and happy.
09-28-2018 08:11 PM
shay2nak Wow, can't believe these damaged cars.
09-28-2018 12:18 PM
Kubera Your crash box looks fine, glad to see it was not damaged. The suspension points also look good too. I would be comfortable starting the rebuild process from this point on.
09-28-2018 12:09 PM
Jaguar A few more.
09-28-2018 12:07 PM
Jaguar Here's a few close ups of the front.
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