Tom Jones' 1967 Lotus Elan S3 DHC restoration
My Elan S3 DHC restoration thread (picture heavy)
Read the full write-up at My Elan S3 DHC restoration thread (picture heavy) ↗
Photo: My Elan S3 DHC restoration thread (picture heavy)A 1967 Lotus Elan S3 DHC SE revived after fifteen years off the road
Tom Jones bought a dormant 1967 Lotus Elan S3 DHC from Maine and used the forum to confirm it was a genuine Type 45 Special Equipment car before working through the fuel, brake and electrical systems to get it running and driveable again. He then moved into interior strip-down and his first fiberglass body repairs, documenting each step and the mistakes along the way. The thread is useful for its detailed identification discussion and its honest account of a first-time owner learning brake, wiring and fiberglass work.
Specs
As stated in the original write-up.
- Model
- Type 45 Lotus Elan Series 3 DHC, Special Equipment (SE)
- Chassis number
- 6697, factory invoiced 17 April 1967
- Tyres
- Maxxis MA-202 all-season tyres fitted
- Brakes
- Girling master cylinder and caliper rebuild kits fitted
- Electrical
- New clear-lens headlights with replaceable bulbs and a new Lucas indicator relay fitted
Parts used
Parts named as used in the original write-up, grouped the way the Parts page groups them. Where one of the shops we index lists the same thing for this car, it is shown underneath with a link to the shop.
Fuel & Ignition 1
- Fuel pump rebuild kitPaul Matty
Used to rebuild the mechanical fuel pump, including diaphragms
In the shops
AC Delco Fuel Pump Rebuild Kit ↗
Sports & Classics· $34.95 USD
AC Delco Master Fuel Pump Rebuild Kit Austin Nash Lotus Triumph Volvo ↗Sports & Classics· $39.95 USD
Facet Fuel Pump Kit ↗
TRGB· £127.55 GBP
Cooling 1
- Upper and lower radiator hosesRD Enterprises
Replaced a dry-rotted, leaking upper hose and its lower pair
In the shopsRadiator Bracket Grommet Set, Upper and Lower (Mini) ↗
bpnorthwest.com· $1.56 USD
Upper Radiator Hose with Temperature Sensor Port for NC ↗
Flyin' Miata· $37.99 USD
Austin/MG Ball Pin (Upper/Lower) ↗Sports & Classics· $39.95 USD
Gearbox & Drivetrain 1
- Girling clutch master and slave cylindersPaul Matty
Replaced seized original clutch hydraulics
In the shops
Girling Clutch Slave Cylinder (3/4 bore) ↗Sports & Classics· $119.95 USD
Girling Clutch Master Cylinder (AC/Lotus) ↗Sports & Classics· $189.95 USD
TVR Griffith 200 Girling Clutch Master Cylinder ↗Sports & Classics· $269.95 USD
Brakes 2
- Girling brake master cylinderPaul Matty
Replaced the seized original master cylinder
In the shops
Triumph GT6 MKI/Lotus Elan Girling Brake Master Cylinder ↗Sports & Classics· $269.96 USD
Girling Tandem Brake Master Cylinder Rebuild Kit ↗Sports & Classics· $79.95 USD
Girling Master Cylinder Seal Kit ↗
Moss Motors – Triumph TR6/TR250· $14.00 USD - Used right front brake caliper and rebuild kitRD Enterprises
Replaced the sticking original caliper after rebuild
In the shops
Lotus/Jensen/Triumph Caliper Rebuild Kit ↗Sports & Classics· $169.95 USD
Elva/Lotus/Marcos/Triumph Caliper Rebuild Kit ↗Sports & Classics· $139.95 USD
Lotus Elan Rear Caliper Rebuild Kit (Stainless Pistons & Seals) ↗Sports & Classics· $159.95 USD
Wheels & Tyres 1
- Maxxis MA-202 tyresMaxxis
Replaced dry-rotted, flat-spotted original tyres
Interior 4
- Tenax fasteners
New studs fitted during interior and top reassembly
In the shops2BA Nut and Washer for Tenax Fastener ↗
Kelvedon Lotus (Kelsport)· £0.20 GBPTenax Top Fastener Y014A ↗
MGOC Spares· £4.25Tenax Fastener Peg - Long ↗MGOC Spares· £2.75 - Aluminum seat rails
Fabricated to replace rusted original steel seat rails
- Recycled leather cloth
Used to recover repaired door panels
In the shops
Leather Cloth (1m x 1.3m) ↗MGbits4U· £81.84 GBP
Leather Cloth (1m x 1.3m) ↗Leather Cloth (1m x 1.3m) ↗ - Interior carpet set
Installed new carpet and carpeted fabricated interior panels
Electrical 2
- Clear-lens headlights
Fitted in place of originals, with replaceable bulbs
In the shops
Clear Sidelamp Lens ↗
Lens, side, glass, clear ↗Moss Europe (UK)· £17.50 GBP
Lucas L717 Clear Indicator Lens ↗Sports & Classics· $19.95 USD - Lucas indicator relayLucas
Replaced the old relay to correct slow-flashing turn signals
In the shops
Oval Indicator Lamp Lens ↗Moss Motors – Triumph TR6/TR250· $95.37 USD
Fog Lights, Lucas Classic ↗Moss Motors – Triumph TR6/TR250· $243.48 USD
Lucas C40 Conversion Kit (Positive Ground) ↗Moss Motors – Triumph TR6/TR250· $1,017.14 USD
Tools & Workshop 1
- Knockoff removal toolRD Enterprises
Purchased for removing the knock-off wheel hubs
In the shopsTrim Removal Tools ↗MGOC Spares· £12.00
Rear Flange Removal Tool ↗Betaset (France)· €235.44 EUR
Hub Cap Removal Lever Tool ↗MGOC Spares· £5.90
Other 1
- Fuel filler grommetRD Enterprises
New grommet fitted at the fuel filler
In the shops
Fuel Tank Filler Grommet (Triumph) ↗bpnorthwest.com· $3.23 USD
Herald & Vitesse Fuel Tank Filler Neck Grommet/Seal ↗TRGB· £13.15 GBP
Grommet, Filler Spout ↗Moss Motors – Triumph TR6/TR250· $20.99 USD
Photos
126 pictures collected from the write-up, in the order they were posted, shown from My Elan S3 DHC restoration thread (picture heavy). A picture opens larger here, with the way through to the page it is on.
My Elan S3 DHC restoration thread (warning: picture heavy) 40this post at My Elan S3 DHC restoration thread (picture heavy) ↗
My Elan S3 DHC restoration thread (warning: picture heavy) 40this post at My Elan S3 DHC restoration thread (picture heavy) ↗
My Elan S3 DHC restoration thread (warning: picture heavy) 40this post at My Elan S3 DHC restoration thread (picture heavy) ↗
My Elan S3 DHC restoration thread (warning: picture heavy) 6this post at My Elan S3 DHC restoration thread (picture heavy) ↗
How it was done
Starting condition
Tom Jones collected the Elan from Maine after it had reportedly sat since being parked running over fifteen years earlier. Forum members helped confirm from the chassis plate, trim and badging that it is a genuine Type 45 Series 3 DHC Special Equipment car, chassis 6697, despite some non-standard parts such as later boot hinges and a possible column lock fitted along the way.
Getting it running
He tested the electrics, finding most systems worked, then drained old fuel from the tank, removed the seized brake and clutch master cylinders, pulled the Weber carburettors to reach the fuel pump, and ordered replacement Girling parts and a fuel pump rebuild kit. After cleaning the carbs and refitting everything, the engine started and ran smoothly, and he drove the car on the road for the first time in years.
Brakes, cooling and running gear
A sticking front caliper was rebuilt with parts from RD Enterprises, including freeing a stuck piston. Upper and lower radiator hoses were replaced after the old upper hose was found leaking, and the coolant was flushed. New Maxxis tyres were fitted to replace dry-rotted, flat-spotted originals, though one wheel was found to be slightly bent.
Electrical tidy-up
Tom worked through unidentified relays and wiring with help from other owners, concluding much of the loom had been altered from standard. He replaced the headlights with a clear-lens version, fitted a new Lucas indicator relay to fix slow-flashing signals, and cleaned up and reconnected bullet terminals with dielectric grease throughout.
Interior strip and body repair
He removed the seats, rotten carpet, seat belts and roll bar, finding the rusted seat rails needed replacing. Deciding against pressboard, he began repairing fiberglass sections himself for the first time, rebuilding the broken boot hinge mounting areas and the rear deck tray, and fabricating a new fiberglass panel between cabin and boot after the original was missing or damaged.
Interior reassembly
New carpet was fitted along with newly carpeted interior panels, and the roll bar and top frame were sanded, painted and reinstalled. New Tenax studs and stainless hardware were used throughout, and new aluminum seat rails were made to replace the rusted steel originals. Door panels were repaired, foamed and recovered in recycled leather cloth, though fitting the material around the recesses proved difficult.
Progress so far
By mid-2019 the interior work was largely complete, though Tom was not fully satisfied with the door panel finish and considered having them redone professionally. Paint colour had not been decided, with period Carnival Red or Lotus Yellow under consideration, and further bodywork and painting remained planned but not yet started.
A summary in our own words. The full account, with all its detail, is in the original write-up: read it at My Elan S3 DHC restoration thread (picture heavy) ↗
Worth knowing
- Scrape any old carpet residue fully off a panel before laying fiberglass, to avoid trapped air pockets.
- Fitting recycled leather cloth tightly over door panel recesses without exposed cuts proved very difficult, perhaps a job for a professional next time.