Cables and controls…
Ok, the engine running and its all smiles. Let get the cables and controls sorted in preparation to getting the car back on its wheels.
The clutch line
In the Sun kit you will get a 90 degree elbow to fit to the clutch line.
Cut the Lotus fitment off and tidy up the end - a good quality ’sharp’ pair of side cutters are ideal here. Slide over the fixing nut.
Insert the brass collar.
Push the end on and tighten up.
Connect to the gear box and bleed using an ‘Easi-bleed’ pressurised system to bleed the clutch.
Note: I had a minor panic here as the clutch line seemed to be too short, just give it a tug (not to hard) and you’ll find that it easily reaches.
Throttle Cable
Another job for the Dremmel here, and some trial and error.
Cut the nipple off the end on the throttle cable and pull about 30cm back through from the pedal box.
Cut the adjuster end from the cable and place in a vice. Drill out the unthreaded end of the adjuster so that you can re-insert the cable sheath.
Shorten the cable sheath by 6-7cm and push the cable back through from the pedal box. Push the adjuster back over the end of the sheath.
Tip: Demon Tweeks sell an adjustable nipple end for £2-3 [Solderless Nipple]. Push the cable through it and tighten the screw.
In the picture below I made my own nipple and retainer. You would be better off buying the Demon Tweeks version as it will save you a couple of hours messing around.
Remove the adjuster plate from the throttle body and use a Dremmel to trim and the ends off. Then use a round file to increase the diameter of the whole.
Re-fit the adjuster plate and bolt in the cable, so this its taught and throttle butterfly is fully closed.
Now, adjust the foot well stop so that you get 100% travel and the butterfly fully opens.
Gear Linkage
Again, this is pretty straight forward, but you will need to cut about 1cm from the connecting rod on the left hand side.
Adjust the arms so that you get full travel of the gear stick and you can select reverse etc.
Drive shafts
Installing the drive shafts is a little awkward. The left hand shaft requires someone under the car to guide the inboard end in squarely.
Tip: Use some plastic tubing to vent the drive shaft boots at the narrow end. I used ‘cotton-bud tudes’ cut down and the cotton removed.
I took the opportunity to replace both rear wheel bearings and both rear toe-links. Also the upper hub carrier bolts have been strengthened, so contact your Lotus dealer for any update information.
On the left hand side, file or use a Dremmel to make the drive shaft hole bigger. The shaft run very close so it essential that you get this right. Don’t forget to paint around the hole to prevent rust.
No such issues on the right hand side.
NOTICE: Fill the gearbox with oil NOW. Refer to your Honda manual.
Time to refit the handbrake cable, fit the brake discs and pads then bleed the brakes. Again consult your Lotus manual then check and double check everything.
Tip: Probably a good idea to use some ‘Stop-Quick’ to clean the brake discs and pads.
Next, refit the body and mount the electrics.