Enforced Winter Fettle!

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*ian_pez*
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Enforced Winter Fettle!

Post by *ian_pez* » Tue Feb 07, 2017 10:47 am

I was competing in an Autosolo on Sunday at Trax Preston. I completed my first run of the day without too much drama although damp kart tracks are pretty slippy! On my second run, I ran over the base of a cone at about 20 mph and then spun on the next left hand bend.

Toe link failure on the off side scuppered my fun for the rest of the day :(

I spent the rest of the day arranging trailers and driving back and forth to friends houses until the Elise was back in my garage and the trailer back at my friends.
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Looks like metal fatigue to me. There is only about 1/2mm of shiny metal, the rest is dull and different shades.

Glad it didn't fail when pushing on :Censored:
Ian

Bury, Lancs.
Elise S1 Millennium

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oggy
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Re: Enforced Winter Fettle!

Post by oggy » Tue Feb 07, 2017 1:15 pm

lucky indeed, on the bright side time for an upgrade :Ok2:
I feel a change coming :unsure:

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Tue Feb 07, 2017 2:06 pm

Indeed!

I was going to do a suspension refresh whilst its in bits as the wishbones look horrible.

Hopefully I'll be able to get the bolts undone without too much pain.
Ian

Bury, Lancs.
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Jono
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Re: Enforced Winter Fettle!

Post by Jono » Tue Feb 07, 2017 3:24 pm

Wow! That could have been nasty. :blink: I think a refresh is definitely in order.

Wish I'd known you were in Preston. :D
Last edited by Jono on Tue Feb 07, 2017 4:18 pm, edited 1 time in total.
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Rob P
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Re: Enforced Winter Fettle!

Post by Rob P » Tue Feb 07, 2017 3:39 pm

Wow that was a lucky escape Ian, shame about missing most of the days fun though, however glad to hear you are OK and with an upgrade on the way I'm sure there will be more fun to be had soon
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Martin 111S
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Re: Enforced Winter Fettle!

Post by Martin 111S » Tue Feb 07, 2017 7:53 pm

Very lucky, as you say could have been a lot worse. Glad you're ok and live to race again :)
Find a Path That Captures Your Heart and Follow It to Its End !!

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Tue Feb 07, 2017 8:09 pm

Jono wrote:
Tue Feb 07, 2017 3:24 pm
Wow! That could have been nasty. :blink: I think a refresh is definitely in order.

Wish I'd known you were in Preston. :D
I wasn't there that long Jono :)

There is more fun to be had in the future events though. I'll let you know when I enter next.

Ian
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brooke bond
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Re: Enforced Winter Fettle!

Post by brooke bond » Tue Feb 07, 2017 10:09 pm

Let me know if you do another Solo. I thoughly recommend Spitfire engineering kit for your replacement, its expensive, but top quality kit , if you plane to keep it for a while.
Xav

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 08, 2017 5:29 pm

brooke bond wrote:
Tue Feb 07, 2017 10:09 pm
Let me know if you do another Solo. I thoughly recommend Spitfire engineering kit for your replacement, its expensive, but top quality kit , if you plane to keep it for a while.
I'd like the Spitfire kit but its a bit too much for me unfortunately, especially as I'm now going to need ball joints and bushes. No point not replacing those as the wishbones are going to be removed for painting.

O/S now in bits ready for cleaning and paint.
WP_20170208_002.jpg
If anyone has any spare wishbone bushes or top and bottom ball joints that they want to sell on, please let me know. :D
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Ian

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oggy
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Re: Enforced Winter Fettle!

Post by oggy » Wed Feb 08, 2017 8:18 pm

Don't go for any old ball joints stick to the eliseparts, eliseshop or seriously lotus ones a bit more expensive than the motor factor ones but its worth it, they will fit properly. As for wishbone bushes either stick with OEM lotus ones or the spherical bearing type don't bother with any nylatron or poly type bushes they don't wear well. Just my two penneth but i wish I'd listen to the advice I was given when I did my first refresh it would of saved me money long term.
I feel a change coming :unsure:

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brooke bond
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Re: Enforced Winter Fettle!

Post by brooke bond » Wed Feb 08, 2017 8:35 pm

I have used the std seriously lotus kit on my Honda and very happy with it.
Xav

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 08, 2017 10:02 pm

Cheers guys, thanks for the advice.
Ian

Bury, Lancs.
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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Sat Feb 11, 2017 6:30 pm

A little more progress today, as I have now stripped the n/s rear suspension from the car.
Most of the bushes seem in good condition just a couple showing a little wear.

So the shopping list so far is :
The Elise-Spares rear toe link kit
4 x ball joints
2 x wishbone bushes
Rear suspension bolt kit
Handbrake cable

I will be blasting the wishbones next week and then repainting them, black probably. I will also be giving the hubs a wire brushing and re painting too.

Hoping to get it back together for the Mini Miglia touring assembly in March.
WP_20170211_001.jpg
Ian

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ANWAG
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Re: Enforced Winter Fettle!

Post by ANWAG » Wed Feb 15, 2017 2:51 pm

To me, the failure looks like classic high cycle low stress bending fatigue propagating from a sharp corner and/or where corrosion is present at a change of material section. (Sometimes also called corrosion fatigue). The dull areas are where the initial crack has spread from the corroded or sharp corner or a combination of both until there is sufficient metal left to support the structure. Then it fails catastrophically. Running over the cone would have been the proverbial straw that broke the camel's back. There appears to be a lot of corrosion on the hexagonal section. This is a very common problem especially on rotating equipment shafting or static items subject to fluctuating bending stresses. Suggest you also replace opposite side as well and protect with a goodly coat of Hammerite or similar. Make certain whoever makes the new parts puts a generous radius on all changes of section. Incidentally, changing the material to a 'harder' or tougher steel won't make any difference and non corrosive stainless steel although it won't corrode will not have the same tensile strength.

I'm down at Chris Niels Sunday morning if you wish to discuss the issue but bring the broken bit with you.

Good Luck
Andy

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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 15, 2017 4:52 pm

Thanks for your input Andy. The hexagonal section is actually the locking nut for the rod end thread.
I'm getting the replacement toe link kit from Elise-Shop which should be less prone to this type of failure.

I would have liked to see you at Christopher Neils on Sunday but unfortunately I'm in work.
Ian

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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 15, 2017 8:07 pm

I'm on with the wishbone refurb now. A friend of mine has a soda bath which cleans rust like magic!

I'll be pushing the ball joints out of the cleaned wishbones tomorrow then painting before some shiny new ones.
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Re: Enforced Winter Fettle!

Post by oggy » Wed Feb 15, 2017 8:27 pm

That looks a lot less messy than sandblasting :Ok2: what paint are you going to use?
I feel a change coming :unsure:

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Jono
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Re: Enforced Winter Fettle!

Post by Jono » Wed Feb 15, 2017 8:59 pm

Looking good Ian! Enjoying the fettling updates too! :Clapping:
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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 15, 2017 9:02 pm

oggy wrote:
Wed Feb 15, 2017 8:27 pm
That looks a lot less messy than sandblasting :Ok2: what paint are you going to use?
Not sure yet Oggy, I've used smooth hammerite in the past and had good results with it.

What do you recommend?
Ian

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Andy C
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Re: Enforced Winter Fettle!

Post by Andy C » Wed Feb 15, 2017 9:28 pm

*ian_pez* wrote:
Wed Feb 15, 2017 9:02 pm
oggy wrote:
Wed Feb 15, 2017 8:27 pm
That looks a lot less messy than sandblasting :Ok2: what paint are you going to use?
Not sure yet Oggy, I've used smooth hammerite in the past and had good results with it.

What do you recommend?
I used an undercoat of kephos and top coat of xylan when i refurbed my wishbones and a few other parts...should last a good few years.
S1 Sport 160 Starlight Black
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oggy
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Re: Enforced Winter Fettle!

Post by oggy » Wed Feb 15, 2017 9:46 pm

*ian_pez* wrote:
Wed Feb 15, 2017 9:02 pm
oggy wrote:
Wed Feb 15, 2017 8:27 pm
That looks a lot less messy than sandblasting :Ok2: what paint are you going to use?
Not sure yet Oggy, I've used smooth hammerite in the past and had good results with it.

What do you recommend?
I've used por15, this seems to be recommended by most of the threads on seloc who have done similar refurbs. One thing I have found using Hammerite and some industrial paint I got, at this time of year it's like trying to paint with glue but the por15 went on a treat when I did mine with hammerite they were shite.
I feel a change coming :unsure:

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ANWAG
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Re: Enforced Winter Fettle!

Post by ANWAG » Wed Feb 15, 2017 11:03 pm

*ian_pez* wrote:
Wed Feb 15, 2017 4:52 pm
Thanks for your input Andy. The hexagonal section is actually the locking nut for the rod end thread.
I'm getting the replacement toe link kit from Elise-Shop which should be less prone to this type of failure.

I would have liked to see you at Christopher Neils on Sunday but unfortunately I'm in work.
Wasn't sure from the photo what the hex section was. The fracture crack will have started at the corroded thread root. Not very often you hear about it in the motor industry. If you are interested have a look at the images on the link below.
https://www.google.co.uk/search?q=corro ... CtkQsAQINQ

Happy viewing
Andy

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Thu Feb 16, 2017 3:41 pm

Ball joints removed from one side today.
Blasted a bit of corrosion from the ball joint holes and will be getting on with painting them tomorrow.
Going for some zinc under coat and por15 topcoat in black.
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WP_20170216_001.jpg
Ian

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Sat Feb 18, 2017 6:21 pm

Paint starting to go on.
Two coats of zinc primer and then the por15.
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Ian

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*ian_pez*
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Re: Enforced Winter Fettle!

Post by *ian_pez* » Wed Feb 22, 2017 6:30 pm

3 of the wishbones now ready for their ball joint. All painted and looking good.


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Shiny bits have now arrived.
Might have to spend some time in the garage this weekend!!
WP_20170222_001.jpg
Ian

Bury, Lancs.
Elise S1 Millennium

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