The Lotus Esprit, pack 4

[Mark A]

Stage 26, assembling the header tank and fitting the clutch lever

 

Start by inserting the long arm of part 26-D underneath the carbs. Then fit the short end onto the carburetor pin. 

Then fit the long side of the pipe onto the second carburetor.

 

Next, fit the oil pipe (26-E) onto both the air box and the oil cap.

 

Now, we fit the clutch cylinder dust cover to the transmission, followed by the clutch lever. Both of these are pressfit into place.

 

Next, fit the clutch spring to the bell housing and the clutch lever.

Lastly, assemble the header tank and bracket.

Stage finished!

[Mark A]

Stage 27, Attaching the inner right side member

Start by attaching the header tank from the last stage to the frame member, This is held in place with a DS06 screw.

Now, mount the frame member to the indicated screw post and secure with a DS02 screw.

Next, install the silver water pipe as indicated in the directions, long end first.

Following the installation of the water pipe, place one end of the small hose onto the water pipe pin. then, push the other end onto the pin that is found on the L shaped hose from the last stage.

Now, push one end of the large hose onto the large pin found on the water pipe. and route the hose to the pin found on the intake manifold assembly. push the other end onto the pin on the manifold.

 

Stage finished.

[Mark A]

Stage 28, Attaching the left and right side members

 

This is a quick stage. We start with the right hand side member. align it with the 3 pins on the chassis, and secure with 3 DS06 screws.

Repeat for the left side.

The next step has a somewhat fragile part, so exercise caution so as to not break the pipe off of the cap. 

Fit the cap onto the header tank and let the lower end of the pipe hang free behind the frame members and next to the header tank bracket.

 

Stage finished.

[Mark A]

Stage 29, fitting the right brake caliper

 

 

Fix the brake caliper to the mount using 2 DS23 screws, then mount the caliper to the frame cross member with 2 DS02 screws.

 

Stage finished.

[Mark A]

Just now, Mark A said:

Stage 29, fitting the right brake caliper

 

 

Fix the brake caliper to the mount using 2 DS23 screws, then mount the caliper to the frame cross member with 2 DS02 screws.

 

Stage finished.

 

[Mark A]

Stage 30, fitting the left brake caliper and attaching the cross member

 

Assemble the brake caliper as previously, and attach to the frame cross member.

Attach the frame cross member to the side members using3  DS02 screws and 1 PS14 screw. Then attach the air induction hose to the air box and fix in place with a DS02 screw.

Lastly, fit the rod to both the bell housing and to the transmission. The bell housing has a receptacle for one end, while the other end is held in place with a PS03 screw.

 

Stage finished.

[Mark A]

Stage 31, fitting carpet to the rear floor

Start by fitting the cylinder connection to the cylinder. This is a press fit. Next, place the cylinder over the two pins on the rear floor, and press firmly into place,

 

Next, locate the right hand piece of carpeting for the wheel well. This is piece R-2 as shown in the diagram in the build instructions. Peel the backing off, and carefully fit into place. I recommend "dry fitting" the carpet into place with the backing paper still on, so you get an idea where to put it down. Once the backing paper is off, its a one shot deal to get it into place.

Next, carpet piece R-3 into place, along with piece R-1, which goes between the two prior pieces.

Repeat for the left side.

 

Lastly, fit the interior floor to the chassis, and secure with 4 DS02 screws.

 

Stage finished

[Mark A]

Stage 32, threading wires through the transmission tunnel

Start by threading the 3 indicated wires through the hole in the transmission tunnel, then loop the wires around the left side of the rear floor.

Then, using the provided wire brackets, fit the wires into the channel, and clip into place.

 

Repeat this sequence for the right side, using the three remaining cables.

 

Lastly, pull the loose ends of the cables SNUGLY against the until they are tight against the frame uprights. Then, route the wires through the channel and secure with a large wire bracket. Then, move the cables through the square hole in the frame, and secure with a medium wire bracket.

 

Stage finished

[Mark A]

Stage 33, Fitting the right and left floor panels

Start by peeling off the left piece of carpet from the backing sheet, ans placing it onto the left floor panel, Then repeating for the right side.

 

Place the left floor panel into position, and secure from the underside with 2 PS05 screws, then repeat for the right side.

Stage finished.

 

[Mark A]

Stage 34, fitting the rear floor panel

In the same manner as the last stage, peel the piece of carpeting from the backing paper, and place it onto the floor panel.

 

Next, Install the floor panel onto the chassis with 3 PS05 screws. from the underside.

Now, take the thin strip of carpeting, and place it over the screw holes in between the right and left sides. Note that there are 2 rectangulat holes in the strip, and place these over the matching holes in the sub floor.

Lastly, hook up the cable from the distributor to the cylinder.

 

Stage and pack finished!