Lotus Elise, mounting a new Crashbox -Start to end

[@VincentChiaro]

Great video! You are very meticulous with your work! I recently did this on a wrecked Exige that I bought. Getting the old box off was a lot of work, more than mounting the new one. Two other small tips to add: 1 - Put a piece of radiator hose on the two coolant hard mounts coming through the aluminum bulkhead. The clearance between the hose and the crash box is quite tight and if you aren't careful you could wind up without enough space to get the hose + hose clamp on there after it's mounted. 2 - This is unconventional, but when we mounted it we actually drilled into the aluminum bulkhead where the box mounts and put in two small threaded "riv-nuts". This worked out great because they helped support it during the gluing and we were able to adjust the angle to make sure it was level simply by tightening or loosing those two small screws.

[@D3Sshooter]

Vincent Chiaro very good tips. Thanks for the comments

[@Rally_Dude]

Thanks for going to all this trouble to record your work. Your record is really helpful to me as I disassembled my car some years ago, and I am only just putting it back together now. The clam removal video was really good for reminding me all of the attachments. I haven't needed to do a crash box, and I hope I never will. Great to have this reference if its ever needed.

[@D3Sshooter]

Justin Northage txs justin

[@georgekannavas6301]

Thanks for a very informative video. It’s a job I would not have taken on if not for this.

[@pbysome]

When using a level one should turn it around and check any discrepancy in the level itself if there is simply halve the error. I always do this in the shop before I purchase a spirit level.

[@D3Sshooter]

Thank you for the comments

[@muckman5509]

i cant get over this why didn't they just install 4 aliment holes for this. for something so important they really have left alot of room for error. Very good work on your behalf. Where did you get all the info? IM new to lotus and would like to know where to get the factory workshop manuals and parts catalogue .

[@D3Sshooter]

Thanks for the comments, yep sometime one wonders why designers do the things the way they did them. Got the info by looking at many different repairs at a local Lotus garage. And i did work on kit cars and cars before...

[@TheDaf95xf]

Great video Steve 😄

[@D3Sshooter]

TXS for your comments

[@McSlySenior]

Btw i love your videos :-) just noticed the differince on the mounting

[@D3Sshooter]

TXS, just have a look at the video where we mount the radiator, you will see that I have them fitted properly during that work

[@mykiman5955]

Hi, Im in the process of buying a 2015, 1.6 club racer with 11,000miles on the clock. Are there any major issues i should look out for???

[@D3Sshooter]

Txs for the comments, that is good to see and hear. There are many area's to check. I have video on my channel, buying a lous elise.

[@mykiman5955]

Yeah, I watched that earlier this week. Its from a Lotus dealer in Edinburgh and seems in fantastic condition with full history. Ive got a full years warranty so lets hope all will b good 👍

[@McSlySenior]

For the crash box you mounteded it on top of the side brackets and not below and inside of the side brackets. The side brackents were the ones you drilled out the rivets on. You can see that in you video on removal of the crash box.

[@D3Sshooter]

Yes indeed, it provided some support during the mounting of the crash box, and kept the crash box wings ( bottom) open enough . But note that the bracket was very loose on the frame... Well spotted

[@harald.370]

First time I noticed that the car is RHD; will you consider rebuilding it to LHD as well in this project? That would be very interesting to see 👍

[@D3Sshooter]

Hi Harald, First txt for the comments. No I am not going to mod the RHD to LHD. The reason is that this is a 135R and as far as I can track it only a handful were made (180). All RHD. So I will keep it original. You will see how I fix the overtake problem with a RHD ( small camera and iPhone).

[@chrismacleod3947]

why do i need to know this am i going to crash

[@muckman5509]

why in hell didn't lotus just install alignment marks like every other part thats installed on a car lol

[@D3Sshooter]

Thanks for the comments

[@apricusstainedglass]

Hi Steve, back in 2011 Lotus started compiling a 135R Register and we're requesting owners contact them with current details and whereabouts. I'm sure they would appreciate knowing about yours now. They can also tell you what they already know about your car. Andy Graham in Lotus Archives at [e-mail] or telephone [phone].

[@D3Sshooter]

Tango Nuevo hi tango. Txs for commenting and i will fir sure contact them. Txs again