Winston's 1969 Lotus Elan S4 restomod
S4 restomod covid project
Photo: S4 restomod covid projectA 1969 Lotus Elan S4 rebuilt as a stiffened, wide-wheel restomod
Winston (forum name ElanCustom) took a rough federal 1969 Elan S4 and rebuilt it during a long quarantine, applying 26R-style chassis stiffening, a reworked twin-cam engine, adjustable suspension and wide billet wheels under flared arches he fabricated himself. The thread documents extensive fiberglass door and shutline work alongside detailed mechanical upgrades, with the owner discussing trade-offs in handling and weight.
Specs
As stated in the original write-up.
- Engine
- Twin-cam, bored +.040 with JE forged pistons, Weber head with 1.625" intake valves, Norris 407 cam (280 duration), built by Paradise Motorsports
- Carburetors
- New DCOE 40 151 Webers
- Ignition
- Pertronix 2 distributor
- Charging
- 40 amp Denso mini alternator
- Starter
- Gear reduction clockable starter
- Clutch
- Aluminum flywheel with street 8.5" clutch
- Cooling
- 26R-style wide radiator, swirlpot, Dave Bean removable cassette water pump, electric fan with shroud
- Fuel tank
- Aluminum, from RD
- Gearbox
- Rebuilt 4-speed
- Driveshaft
- Rebuilt
- Differential
- Rebuilt with limited slip added
- Driveshafts/CVs
- Billet axles with CV joints replacing rubber donuts
- Chassis
- 26R-style frame mods plus removable Monte Carlo bar, removable crossbar under oil pan, reinforced motor and steering box mounts, front jack point, tow hook, doubled rear A-arm pivots, triangulated tunnel corners, gusseted rear strut mounts
- Suspension
- Front and rear adjustable ride height, rear adjustable camber and toe in, by Barry Spencer at Spencer Motorsports
- Brakes
- Calipers rebuilt by Ken at Dave Bean
- Steering
- Steering box rebuilt by Dave Bean, true CV joint on steering column
- Wheels
- 15 inch billet aluminum wheels by Image Wheels UK, front 5.5J, rear 6.5J
- Tyres
- Dunlop Direzza III, front 195/50R15, rear 205/50R15
- Electrical
- Complete new British Wire harness, 26R-style headlights with LEDs
- Interior
- Aluminum trim panels replacing cardboard/Masonite panels, wooden boot floor, Caterham headrests
- Body
- Fender flares built from original wheel openings tilted 30mm at the top; 16 gauge steel bulkhead added in boot
- Weight
- About 1640 lbs measured on a truck scale, before wooden boot floor and Caterham headrests were added
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.
Engine 4
- JE forged pistonsJE
Used in engine bored +.040
In the shops
Forged Piston Set, 83.5mm, 0.25" Intruder, 12.5:1 Compression ↗Lotus Marques· $822.10
Forged Piston Set (4) ↗
Retro Engineering· £600.00 GBP
Kameari High Compression Forged Piston Kit ↗
JDM Car Parts· $1,269.99 USD - Weber head with 1.625 inch intake valvesChris at Elans and Sevens
Purchased head fitted to engine
In the shops
Crossflow Head Gasket Set for Weber Carburettor ↗
C Bradley Motorsport· £52.00 GBP
Head Gasket Set - Ford Cortina Mk2 1300, 1600E & 1600GT (X-Flow OHV, Weber Carbs, 1967-70) ↗
Other Classic Car Parts Wolseley 1500 Saloon Car Parts· £14.50 GBP - Norris 407 cam, 280 durationChris at Elans and Sevens
Fitted to engine build
- Engine buildParadise Motorsports
Complete engine build including bore and pistons
Fuel & Ignition 3
- DCOE 40 151 carburetorsWeber
New Weber carburetors fitted
In the shops
Weber DCOE Carburetor Twin Cable Throttle Linkage Kit ↗
Gartrac· $103.00 USD
Manifold, inlet, Weber DCOE ↗Moss Europe (UK)· £476.26 GBP
Ram Pipe, Weber, 16mm, 45 DCOE ↗Moss Europe (UK)· £40.25 GBP - Pertronix 2 distributor
Ignition upgrade
In the shops
Distributor, Rover V8 with Pertronix ↗
bpnorthwest.com· $381.29 USD
45D4 Distributor with Pertronix Ignitor II ↗bpnorthwest.com· $420.65 USD
Pertronix Distributor (Spitfire 1962-1974) ↗bpnorthwest.com· $232.76 USD - Aluminum gas tankRD
Replacement fuel tank
In the shops
Aluminum Coolant Expansion Tank (NC) ↗
Flyin' Miata· $359.00 USDMoroso Aluminum Coolant Expansion Tank (NC) ↗Flyin' Miata· $359.00 USD
Cooling 4
- 26R style wide radiatorRD
Fitted for improved cooling
In the shops26R Rear Hub Wide Offset (Left Hand) ↗
Kelvedon Lotus (Kelsport)· £179.95 GBP26R Rear Hub Wide Offset (Right Hand) ↗Kelvedon Lotus (Kelsport)· £179.95 GBP
26R Elan Radiator Header Tank / Swirlpot ↗
Tony Thompson Racing· £133.00 GBP - SwirlpotRD
Fitted with radiator setup
- Removable cassette water pumpDave Bean
Fitted to engine cooling system
- Electric cooling fan with shroud
Fitted for cooling
In the shopsFan Shroud ↗Moss Europe (UK)· £42.25 GBP
Fan Shroud ↗Moss Europe (UK)· £24.50 GBP
Cooling Fan ↗
Moss Motors – Triumph TR6/TR250· $0.00 USD
Gearbox & Drivetrain 5
- 4 speed gearbox
Rebuilt
In the shops
Gearbox Rear Oil Seal (Mk3 6-Speed) ↗
MX5 City· $28.13 USD - Driveshaft
Rebuilt
- Differential with limited slip
Rebuilt and limited slip added
In the shops
Salisbury Limited-Slip Differential (Classic) ↗Kelvedon Lotus (Kelsport)· £597.50 GBP
Quaife ATB Limited Slip Differential (English Axle) ↗Kelvedon Lotus (Kelsport)· £637.75 GBP
English Limited Slip Differential (Modern Salisbury Type) ↗Kelvedon Lotus (Kelsport)· £754.80 GBP - Billet axles with CV joints
Replaced original rubber donuts
In the shops
Universal Joint, Axle/Halfshaft (Jaguar 1961-1987) ↗bpnorthwest.com· $21.79 USD
CV Joint Axle/Hub Assembly, TVR 2500M with 5-Bolt R200 Diff ↗
Good Parts· $1,198.00 USDCV Joint Axle/Hub Assembly, TVR 2500M with 6-Bolt R200(B) Diff ↗Good Parts· $1,198.00 USD - Aluminum flywheel
Fitted with street 8.5 inch clutch
In the shops
Lightweight Aluminum Flywheel by Fidanza ↗Moss Motors – Triumph TR6/TR250· $597.25 USD
Suspension & Steering 4
- Front and rear adjustable ride height, rear adjustable camber and toeBarry Spencer at Spencer Motorsports
Suspension geometry adjustment system fitted
In the shopsMK1/MK2 Cortina Spax Adjustable Rear Shock, -2 Ride Height (Single) ↗Retroford (Gloucester)· £141.66 GBPMK1/MK2 Cortina Spax Adjustable Rear Shock, Standard Ride Height (Single) ↗Retroford (Gloucester)· £147.91 GBP
Long 4 Link Axle Bracket for Tarmac (with Camber Bar Holes) ↗C Bradley Motorsport· £26.50 GBP - Rear suspension uprightsDave Bean
Rebuilt
- Steering boxDave Bean
Rebuilt
In the shops
Power Steering Box ↗Moss Motors – Triumph TR6/TR250· $0.00 USD
Manual Steering Box ↗Moss Motors – Triumph TR6/TR250· $0.00 USD
Manual Steering Box Seal ↗Moss Motors – Triumph TR6/TR250· $2.56 USD - True CV joint on steering column
Fitted to front of steering column
In the shops
Steering Column Escutcheon Pair ↗
Sports & Classics· $29.95 USD
Steering Column Joint (U-Joint Type) ↗James Paddock Ltd· £30.95 GBP
Steering Column Knuckle Joint Washer Set (Polyurethane) ↗
Brakes 1
- Brake calipersDave Bean
Rebuilt
Wheels & Tyres 2
- Billet aluminum wheels, 15 inchImage Wheels
Front 5.5J, rear 6.5J, custom fitted under flared arches
In the shops
Billet Aluminum Top Latch Locks, Pair ↗Flyin' Miata· $64.99 USD
Tiger Billet Aluminum Alternator Bracket & Spacers ↗
Classic Sunbeam Auto Parts· $85.00 USD
Billet Aluminum Rear Differential Mount R200 (280ZX) ↗
Z Car Depot· $52.99 USD - Dunlop Direzza III tyres
Front 195/50R15, rear 205/50R15
In the shops
Dunlop Tyres ↗Tony Thompson Racing· £0.00 GBPDunlop 550M 13 CR65 Tyre ↗Tony Thompson Racing· £0.00 GBP
Tyre-4.50" x 19" Dunlop ↗MGbits4U· £275.99 GBP
Body & Trim 2
- Fender flares
Built by Winston from original wheel openings tilted 30mm at the top
In the shops
Speed Forme FRP Fender Flare Set ↗JDM Car Parts· $579.99 USD
Protec Rear Fender Flare Set for Nissan Skyline KPGC10 GT-R ↗JDM Car Parts· $799.99 USD
Protec Front Fender Flare Set for Nissan Skyline KPGC10 2D GT-R ↗JDM Car Parts· $799.99 USD - 16 gauge steel bulkhead
Added below stiffener connecting rear uprights in boot
Interior 3
- Aluminum trim panels
Replaced cardboard and Masonite interior panels
In the shops
Hardtop Trim Fitting Panel (Mk3/3.5) ↗MX5 City· $101.54 USD
Clip Door Trim Panel | Genuine Land Rover MUC3186 ↗Moss Motors – Triumph TR6/TR250· $2.00 USDTrim Panel, rear quarter, British racing green, pair ↗Moss Europe (UK)· £115.00 GBP - Wooden boot floor
Added to trunk
In the shops
Boot Floor Panel ↗
Boot Floor Side RH ↗
Boot Floor Assembly ↗ - Caterham headrests
Fitted in cabin
Electrical 4
- 40 amp Denso mini alternator
Charging system upgrade
In the shops
Nippon Denso 40 Amp Motorsport Alternator ↗Retroford (Gloucester)· £166.69 GBP
Genuine Nippon Denso 50 Amp Alternator (5PK Vee) ↗Retroford (Gloucester)· £264.31 GBP
Complete Zetec Motorsport 50 Amp Alternator Kit (Genuine Nippon Denso, Silver Top) ↗Retroford (Gloucester)· £0.00 GBP - Gear reduction clockable starter
Starter upgrade
In the shops
Gear Reduction Starter ↗bpnorthwest.com· $249.95 USD
Gear Reduction Starter Motor ↗bpnorthwest.com· $269.99 USD
Gear Reduction Starter (Spitfire) ↗bpnorthwest.com· $249.95 USD - British Wire harness
Complete new wiring harness fitted
- 26R style headlights with LEDs
Replaced headlights to allow wheel tub modifications
In the shops
Holley RetroBright LED Headlights, 7" Round ↗Flyin' Miata· $578.00 USD
GTR Lighting Ultra 2.0 LED Headlights (9006) ↗Flyin' Miata· $238.00 USD
Morimoto 2Stroke 4.0 LED Headlights, 9005 (2001-05) ↗Flyin' Miata· $188.00 USD
Other 1
- Catch can
Fitted for crankcase and valve cover vents instead of airbox
In the shops
RADIUM DUAL CATCH CAN KIT ↗
MiataSpeed· $449.95 USD
Cusco Oil Catch Can (AE86 Corolla/Levin/Trueno) ↗
Techno Toy Tuning· $125.00 USD
Photos
45 pictures collected from the write-up, in the order they were posted, shown from S4 restomod covid project. A picture opens larger here, with the way through to the page it is on.
S4 restomod covid project 37this post at S4 restomod covid project ↗
S4 restomod covid project 8this post at S4 restomod covid project ↗
How it was done
Starting condition
The project began with a very rough federal 1969 Elan S4 that Winston took on after early retirement, during a long quarantine period, without deep prior experience in keeping Elans original.
Chassis and suspension work
The frame received 26R-style stiffening: a removable Monte Carlo bar, removable crossbar under the oil pan, reinforced motor and steering box mounts, a front jack point, tow hook, doubled rear A-arm pivots, triangulated tunnel corners and gusseted rear strut mounts. Adjustable ride height front and rear, plus rear camber and toe, were added by Spencer Motorsports. Billet axles with CV joints replaced the rubber donuts.
Mechanical work
Paradise Motorsports built the engine, bored +.040 with JE forged pistons, a Weber head, Norris cam and new DCOE Weber carburetors. The gearbox, driveshaft and differential were rebuilt with limited slip added. Dave Bean rebuilt the brake calipers, steering box and rear suspension uprights, and supplied a removable cassette water pump and 26R-style wide radiator and swirlpot. A new wiring harness, alternator, starter and distributor were fitted.
Body and fit work
Winston fabricated fender flares from the original wheel openings tilted 30mm outward at the top to fit wider wheels, and reworked front wheel tubs. Extensive fiberglass laminating and filling using vinyl ester resin, chopped strand mat and milled fiber filler was used to correct door fit and tighten panel shutlines across the car, plus repairs to lower door corners and floors.
Interior and detail work
Cardboard and Masonite interior panels were replaced with aluminum trim panels, a wooden boot floor and Caterham headrests were fitted, and a 16 gauge steel bulkhead was added in the boot behind the sound deadening. Access panels were added for the rear suspension, and a catch can was fitted for crankcase and valve cover vents.
Wheels, tyres and handling
The car runs 15 inch billet aluminum wheels from Image Wheels UK, 5.5J front and 6.5J rear, on Dunlop Direzza III street-legal autocross tyres. Winston reports the car sticks firmly in corners and feels stable, though less nimble than a stock Elan, and notes the added weight is mostly in chassis stiffening and the larger wheels and tyres.
Progress so far
The car is complete and being driven and enjoyed, with ongoing discussion in the thread about door fit refinements and comparisons with other owners' projects.
A summary in our own words. The full account, with all its detail, is in the original write-up: read it at S4 restomod covid project ↗
Worth knowing
- Sticky autocross tyres add unsprung weight and the owner would choose less sticky all-season tyres next time
- Achieving tight door shutlines after painting required adjusting the striker inboard to correct fit once new seals were less compressed