Lotus Twin-Cam Engine Build

Some recent pictures of Lotus Twin-Cam engine build underway at present.  Customer arrived with a ute load of sundry English Ford engine parts, a "Fordised" and knife-edged forged steel fully-counterweighted Datsun L18 crank and a well-used bare twin-cam head for VRD to combine into an engine.  Unlike the standard TC engine that is based on the 1500 pre-X-flow block deck height and stroke, this engine will be a "tall deck"/long stroke version based on a 711M Ford Escort block.

 

Lotus Twin-Cam Cylinder head on VRD Flowbench

Lotus Twin-Cam Cylinder head on VRD Flowbench

Simple (but accurate) template/slave centre made for marking inlet manifolds to increase size to suit 45DCOE Weber carbs   

Simple (but accurate) template/slave centre made for marking inlet manifolds to increase size to suit 45DCOE Weber carbs

 

Post modification

Post modification

Death by Heli-coil...

Death by Heli-coil...

Rectification of damaged/smeared head bolt washer spot face surfaces as a result of previous use of incorrect washers at these sites.

Rectification of damaged/smeared head bolt washer spot face surfaces as a result of previous use of incorrect washers at these sites.

Increasing depth of LHS engine mount attach threads in freshly bored, decked and line-bored 711M block after removal of 0.450" from LHS engine mount pad to bring transverse block width in to line with that of earlier 120E, 116E, 691M et al pre 711M blocks.

Increasing depth of LHS engine mount attach threads in freshly bored, decked and line-bored 711M block after removal of 0.450" from LHS engine mount pad to bring transverse block width in to line with that of earlier 120E, 116E, 691M et al pre 711M blocks.

One of several mock assemblies to check various fits and clearances including valve to piston and valve to valve clearance prior to final assembly.  VRD dummy tensioner plunger allows tensioner quadrant to be loaded to set chain tension during mock-up without needing to fit front cover

One of several mock assemblies to check various fits and clearances including valve to piston and valve to valve clearance prior to final assembly.  VRD dummy tensioner plunger allows tensioner quadrant to be loaded to set chain tension during mock-up without needing to fit front cover

Clay blobs waiting patiently to be squashed during valve to piston clearance check...

Clay blobs waiting patiently to be squashed during valve to piston clearance check...

CCing combustion chambers with burette

CCing combustion chambers with burette

Fine adjustment to camber volume to equalise CC with slave second-hand valves fitted to protect freshly cut seats

Fine adjustment to camber volume to equalise CC with slave second-hand valves fitted to protect freshly cut seats

VRD combination drilling/welding jig fitted to sump along with VRD windage tray.

VRD combination drilling/welding jig fitted to sump along with VRD windage tray.

Windage tray attach brackets manufactured and fitted with floating and self-locking anchor nuts waiting to be welded to sump interior.  Microstop countersink tool in background used to countersink brackets to accept anchor nut attach rivets.

Windage tray attach brackets manufactured and fitted with floating and self-locking anchor nuts waiting to be welded to sump interior.  Microstop countersink tool in background used to countersink brackets to accept anchor nut attach rivets.

Pre weld

Pre weld

P1010038.JPG
Don't forget the dipstick access hole when making the windage tray....

Don't forget the dipstick access hole when making the windage tray....

Oil suction tube skirt

Oil suction tube skirt

Oil temp sender port and lockwire tab for sump plug and temp sender added to RHS of sump

Oil temp sender port and lockwire tab for sump plug and temp sender added to RHS of sump