Lotus Marques

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The latest product news from Lotus Marques.

Lotus Elan handbrake adjustment nut

Monday, 28 May 2018 17:48 Product News
One factor that influences a poorly adjusted handbrake on any Lotus Elan or Elan +2 is the limited access to the pad adjustment nut.
The adjustment nut (Lotus part number 036J6043) sits inside a recess within the rear caliper handbrake linkage.
The simplest way of making adjustments is by means of a long series socket attached to a suitable ratchet handle.

Standard handbrake adjustment nut and new taller version

To make life easier when adjusting the handbrake, Lotus Marques has designed a taller nut in stainless steel that provides improved access.
By installing a taller nut, the handbrake can be adjusted by a ring spanner, open-ended spanner or a regular socket mounted on a ratchet handle.

Lotus Elan handbrake adjustment nut in stainless steel

The new nuts have been manufactured in stainless steel so they will not rust and become solid on the threaded adjustment rod.
The tight knurled pattern ensures a super fine adjustment when setting the pad friction face to disc distance.
Read more...

Water pump overhaul services offered by Lotus Marques

Sunday, 27 May 2018 12:13 Product News
If you are looking to overhaul a Lotus water pump (twin cam or 900 series) and benefit from an extended service life, then the process begins here at Lotus Marques.

There are a several points to understand before attempting to rebuild an existing pump.
1) If the pump is the original component supplied by the Lotus Factory then it’s going to be approximately 50 years old.
Because of the passage of time it may not be possible to know about the pumps service life (and what and if any corrosion inhibitors have been used)
From 20 years experience of operating a water pump refurbishment program, it is essential to dismantle the pump and pressure test to check for internal porosity (prior to rebuilding)
There is no point rebuilding a pump, installing it on an engine only to discover the pump leaks due to porosity problems.

2) Over the passage of time, any water pump would have been rebuilt many times with kits from various sources.
From experience the mechanical seal and impellor are often substituted with components that deviate from the original dimensions
If anyone is contemplating re-using a worn original impellor then it is unlikely that the new seal installed height is going to be correct.
It is imperative that any new seal is installed at the manufacturers design height to maximise service life.
It is worth noting that the mechanical seal installed height dimension is never provided with any commercially available water pump kit.
If the seal installed height is not observed then be aware to much crush will damaged the seal and to little crush will cause the seal to leak.

The current mechanical seals supplied by Lotus Marques are constructed with a stainless steel-body and are taller than the original component.
Being taller means they are NOT a direct replacement but this does provide an acceptable method of recycling the existing impellor.

Quite often the existing impellor face will show signs of corrosion or wear marks that need to be removed.
Machining material off the thrust face corrects these problems and compensates for the taller seal.
This is also a convenient way of adjusting/setting the seal installed height to manufacturers’ specifications.

The same machining operation provides an opportunity to machine a locating step for the ceramic washer.
Once the correct step dimensions have been machined, the ceramic washer can be fastened to the impellor.
At this point the seal and ceramic washer are lapped together using metal polish to ensure a 100% contact surface area.


Lotus twin cam water pump seal removed   Lotus twin cam water pump seal installation

The pump is then finally assembled, impellor blade gap set and pressure tested to 50psi for Quality Assurance purposes.

Lotus twin cam water pump fully assembled   Lotus twin cam water pump pressure tested to 50psi

At the time of publication, typical Lotus twin cam water pump rebuild costs are typically $300.00 to $350.00
To clarify exactly what may be supplied whilst your Lotus twin cam water pump is being overhauled, here is a list of the relevant parts-
Mechanical seal and ceramic button
Bearing (1/2 inch diameter spindle at both ends)
Alloy spacer
Nytrile O-rings for alloy spacer

Any other new parts required will be charged at additional cost and this includes – impellor, front drive flange, dip-stick tube, timing chain damper pad and fixing screws, timing chain tensioner housing and front crankshaft oil seal.

If there are extraordinary repairs such as welding, installing heli-coils or custom parts, then additional costs will apply.
Our objective is to offer a quality overhaul with lasting results that includes a 2 year warranty.

The later water pumps for Lotus Esprit, Elite, Eclat, Excel and Jensen Healey, overhaul costs start at $150.00.

Lotus Excel water pump with machined housing and impellor   Lotus Excel water pump fully rebuilt

Post Script - 24th July 2019
In 1992 Lotus Marques commenced trading in Australia by offering OEM components to Lotus owners.
As the business grew so did the sales of Lotus twin cam water pump kits.
And as the sales of water pump kits increased so did the number of complaints received about supplying faulty pump kits.
The realisation being Lotus twin cam owners are not pleased to discover a leak from a freshly built pump.
This usually results in the time-consuming process of removing the cylinder head to access the pump once again.

Investigating DIY water pump rebuilds that have produced unsatisfactory results requires a systematic approach.
Diagnosing and rectifying faulty water pumps draws on engineering experience gained whilst employed for 13 years by the Ministry of Defence (United Kingdom)
A part of the engineering discipline instilled at the time was to do things only once and to use time wisely.

To investigate the faulty water pump kits, customers were invited to return their leaking pumps.
Dismantling a number of pumps revealed all components supplied in the kits were of serviceable condition and no faults found.
However, what was discovered was a plethora of introduced problems such as – modified housings, extensive corrosion, porous castings, modified components, non-original impellors, non-standard bearings and sub standard assembly techniques.
This investigation resulted in the development of a number of custom tools that allowed water pumps to be rebuilt in-house with predictable results.

These tools are a part of the dismantling and assembly process and allow critical measurements to be made prior to final assembly.
The last quality assurance check is to pressure test all pumps to 50psi prior to despatch.
This test guarantees Lotus owners the pump will not leak and it can be installed with peace of mind.
This also mitigates phone calls received from DIY installers wanting to discuss “faulty parts” and who is responsible for their leaking water pump.

As previously stated, the components used in water pump rebuilds are not direct fit items.
The OEM mechanical seal was originally manufactured by Dilitex in the UK but sadly this part went out of production many years ago.
Lotus Marques has sourced a superior replacement ceramic seal but it is much taller and cannot be fitted without the right tools and equipment.

It is understandable that individuals and workshops may wish to rebuild the water pump themselves so it’s necessary to find a parts supplier who can provide standard dimensioned components.
From experience, other parts suppliers will have no interest in the pump rebuild outcome and unlikely to honour any form of warranty.
Lotus Marques has a different approach where the focus is on a guaranteed outcome and delivering value for money.

It is worth noting there are several publications that show how to rebuild the Lotus twin cam water pump but fail to discuss any methodology that guarantees the pump will not leak when re-installed.
There are often comments derived from tribal knowledge that state “it takes a while for the pump seal to run-in”
This is absolute nonsense as every water pump that is built with the mechanical seal installed at the correct height will not leak.
Whilst there are alternative mechanical seals that may be substituted, they are not all created equal.
The physical appearance may be similar but the seal installed height will invariably be different.
The installed height dimension is never provided in any of the relevant publications and therefore the rebuild procedure is flawed.
For optimum pump service life, it is imperative that mechanical seal be installed per the manufacturer‘s specifications.

For further information regarding Lotus water pumps, please contact Lotus Marques.
Telephone.   03-9761-1903
Email.           This e-mail address is being protected from spambots. You need JavaScript enabled to view it


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Lotus twin cam performance valve guides

Saturday, 03 March 2018 13:55 Product News
Lotus Marques valve guides are CNC machined from high quality Manganese Bronze material.
These are available in standard size diameter and +0.005 inch oversize.

Lotus twin cam bronze valve guide set

These valve guides have been designed to be used in combination of our low friction nitrided and polished valves.
This valve and guide combination provides an ideal solution for both street and race engine applications.
Building any Lotus twin cam engine with these high quality components offers both performance and longevity.
Installation is simplified as the guides have an integral location step so no circlip is required.
Read more...

Clutch and brake master cylinder adjustable push-rods

Saturday, 27 January 2018 11:57 Product News
If you own and drive an older Lotus vehicle then its quite likely the clutch and brake pedals will have some unwanted free-play.
This may not be immediately apparent but can be checked by pulling the pedal backwards and up towards the seat.
If there is excessive free-play then it can change the correct operating point on the clutch and brake pedals.
An easy way of correcting this problem is to install adjustable master cylinder push-rods.
The replacement push-rods are supplied with threaded section, lock nut and yoke that has a quick release clevis pin.

Clutch and brake master cylinder adjustable push-rods
Read more...

Lotus Esprit and Excel upper gasket set A912E9228W

Monday, 23 October 2017 17:53 Product News
The following gasket set suits all normally aspirated Lotus Esprit and Excel SE and SA models from mid-year 1986 on-wards.
NOTE - The manifold and cam cover gaskets are manufactured from a high quality material based on a blend of Aramid and inorganic fibre bonded with a Nitrile rubber filler.
This gasket material exceeds the operational requirements of the Lotus Esprit 912 engine and can withstand operating temperatures of 300 degrees Centigrade. 
Unlike the original Lotus components, these gaskets are impervious to oil and water so there is no possibility of capillary action taking place between the cylinder head and inlet manifold.

The cylinder head gasket is manufactured from a high quality composite material that can withstand the extremes of constant temperature cycling.
The head gasket is 1.5mm (0.060") thick with a silicon peripheral sealing bead plus surface coating that guarantees a water and oil-tight seal.

Lotus Esprit and Excel upper gasket set A912E9228WLotus Esprit and Excel upper gasket set A912E9228W

This kit also contains Viton 'O' rings that are installed between the camshaft housing and cylinder head oil feed gallery.
Using Viton 'O' rings in this application guarantees there are no high pressure oil leaks between the mating surfaces.

This comprehensive gasket set A912E9228W is priced at $160.00 plus GST.
Overseas customers, please note all advertised prices are in Australian dollars.
Read more...

Lotus Elan 2+2 steering rack tie-rod

Friday, 03 February 2017 10:55 Product News
These high quality tie-rods have been fully CNC machined to the original dimensions and thread sizes which make them completely interchangeable with any Lotus Elan 2+2 steering rack. Unlike our competitors, we choose not to zinc plate and passivate the tie-rods entirely so as to offer corrosion resistance. Installing a zinc plated ball into a hardened retaining cup is going to instantantly contaminate the ball joint with unwanted zinc material. The correct choice of corrosion protection for the tie-rod, is to apply epoxy paint to the exposed shaft section only.

Diameter of the ball is 1.040 inches (26.41mm) and length from end of threaded section to underside of the ball is 6.50 inches (165mm)
Overall design length is 7.520 inches (191mm aproximately)
Detail for tie-rod end is 1/2 UNF x 20 TPI and the thread length is 2.0 inches (50.8mm)
The reference part number for the Lotus Elan +2 tie-rod is LM-026H0005-7
Material is 4140 high tensile steel alloy, and the ball is heat-treated to produce a high quality component.
There is a tapered transition from the threaded section to shank that eliminates stress failure.
There is an additional groove on the tie-rod that prevents the rubber gaiter from moving when fastened.
Individual component weight 230 grams

Lotus Elan 2+2 manufactured between 1967 and 1974

Lotus Elan 2+2 steering rack tie-rodsLotus Elan 2+2 steering rack tie-rods

Lotus Marques supports local industry by manufacturing these steering rack tie-rods in Australia.

Price $120.00 each excluding GST ($132.00 each including GST)
Price for a pair is $220.00 excluding GST ($242.00 for a pair including GST)
Read more...

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