S2 NA + Mods

This is where we proud owners can upload information and pictures of our pride-and-joys (their Exige that is..)
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andybond
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Oh! New bits ahoy! I love working on cars that have new bits. No wrestling with rounded off bits!
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thommo
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I like the shiny exhaust
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Fonzey
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Excellent, I do love a good front clam refurb... although I've done my time now (twice) so happy to follow somebody elses progress instead.

Any temptation to address the fan speed resistor back whilst you're in there?
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jonnyfox
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Might be worth a new condenser is you have AC. You know actually you can get a lot of work done front clam off that's worth while Matt. Seems you have most covered. Before and afters please :D
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matt447
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So what’s the best way to avoid air locks when swapping the radiator? Lift the front of the car as high as possible while swapping? Or not necessary?

Is it all futile given that I’m intending to swap the hoses too? Saying that, I can’t even see how you take the old hoses off - access to the clamps seems to be almost impossible as they disappear into the tub? Or do you remove something else? Haven’t genuinely had a good look yet, so perhaps I’m missing the obvious!

My resistors seem fine at the moment, but the heat has been stuck on hot since I got it over a year ago - I can hear the motor moving, but the flap doesn’t move, so I’ll have a go at that... I ordered a new trinary switch for the AC but it won’t arrive for ages thanks to Lotus on shut down :/ nobody happens to know the Denso(?) part number for that do they? :)

Thanks guys! Looks like Mr Rusty’s Rust Emporium in there at the moment! I suspect most of it is very easily sorted though :)
Last edited by matt447 on Thu May 21, 2020 6:45 am, edited 1 time in total.
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matt447
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The project gets about 30mins a day - lots of different pressures given the current climate :/

Here’s last night’s quick look at the current condition!

ImageImageImage
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Fonzey
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I made no efforts at all to avoid air in the system, which meant it took forever to bleed it out - but it does bleed out eventually. The hoses go under the front crash box and the jubilees are accessible from under there (you'll need to take the front floor panel off if you didn't as part of clam removal)

If doing again (hope not :) ) I would take the top hose off and just fill the new rad up with a funnel until it starts dribbling out... that's probably about the best you can do. Once you start the bleeding process, I had the rear of the car jacked up and put the front down on the floor and just let gravity do its work for a bit with both bleed taps open - then started the car, got it up to temp and just gradually bled out all the air.

If your heater box is coming out to investigate the 'stuck on hot' issue, then I'd highly recommend sticking in the updated fan resistor pack. If you've got the original still it'll be fitted practically on the car floor and will be covered in rust, it WILL fail eventually and as you'll find - getting to it is no short task (but significantly easier if you don't run AC). The upgrade kit is a bit pricey for what it is, but once you've gone to all that effort to get the heater box out you will probably not want to do it again any time soon!
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matt447
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Thanks mate - I just went out to it to squirt the blobs of rust with WD40 to try to convert them back into nuts and bolts... while I was there I had a look and spotted that I need to remove the front undertray off and then the jubilee clips look accessible :)

I’d planned to fill the rad up manually before popping the top hose on - great minds think alike and all that ;)

Regarding the blower issues, I’m going to spray the rust with old-faithful WD40 and try to encourage the flap back into life as best as I can. I think I need to take the clam off again when my trinary switch finally arrives anyway. Strangely, I don’t mind taking the clam off again - it’s not too much trouble if all the bolts aren’t rusted to hell, so no biggie... I decided that if the trinary switch doesn’t fix the air con, then I’m taking AC out completely at that point! Don’t need too many excuses to remove weight in my book - and it hasn’t worked for over a year anyway!

Will let you know when I get it all sorted - might be a few days though :(
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Fonzey
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I had a few sleepless nights over whether or not my AC was worth saving. It was holding back the completion of my maintenance by quite a lot waiting for replacement parts/custom pipes etc.

I'm still torn over it now, I rarely use it - but it does blow beautifully cold now. There's just so much gubbins though, the weight saving must be significant not to mention making maintenance of other areas much simpler. The charge cooler install would have probably been done in half the time if not for AC.

There was an S2 heater box on eBay for a while (can't find it now) which included the updated resistor pack in it for a decent price. That would have been ideal for you as you'd sort the flap and resistors all in one go. There's another one on now but it's listed for S3 cars... not entirely sure how different they are though (if at all?) as they look rather similar.
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matt447
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Anyone know how much the AC system weighs in total? I might leave the pipework in, so that it can be refitted at a later date more easily, but remove the condenser and the pump?

Or I can just leave it... but I do love making it lighter!
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