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FAILURES!
How Delicate IS the original Lotus Seven Design?
A Report and Review by John Donohoe, SimpleSevens.org

Every now and then the question comes up about how 'delicate' the original Lotus Seven design is. There are those who would re-engeineer, rebuild and reinforce the original structure, while others maintain that the original design was perfectly designed for the task at hand.

In an effort to shed some light on the answer to this question, the following anecdotal evidence was collected from a handful of members of the Lotus Seven email list, and is organized and presented here for your interest. Each entry is by a single responder, some had several failures of same or multiple components, while others had single failures. Having heard from about 2 dozen respondents, I must assume that the other 150+ members of the email list have never had a probelm with their Lotus Seven that they consider related to its design :-)

I have sorted the incidents under the headings of their primary systems, and have made an effort to distinguish between failures directly attributable to the design of the Lotus Seven, and those attributable to components which may have failed at an equal rate regardless of the automobile in which they were installed (operator ignorance/error falls in this category but is unspecified.) In this way, I hope to bring a little polish back to the perhaps tarnished reputation of the original design!

I have attributed questionable items to the design lest some folk think I'm biased -- which of course I am :-)))

Leading the report is a thoughtful commentary that was written by one owner who brings up some fairly valid points. I am open to any comments or additional failures any current Seven owner would be interested in sharing!

email SimpleSevens here

One Owner's View
from a member of the Lotus Seven Email list

I suspect that what will mostly be reported are mechanical failures and such that are not a result of the missing or present frame tubes. Remember that the Seven was/is classified as a Sports car, NOT a Race car or Sports Racer. You can look at original Lotus ads of the period to find that out.

I think it is acceptable to view Lotus Sevens when used as race cars or sports racers as slightly fragile when pushed into the extreme situations for which they were not really intended. This fragility is understandable in this case as most race cars have frame tube failures etc. etc. or other damage at some point and time. Whoa . . . even the F-word, M-word, and other pure race cars experience failures and the need to fix them or add braces whatever.

I think that sports cars as a classification limits the amount of expected race use to occasional or even none at all. You can dream that Sevens are/were out and out race cars but face the facts . . . they weren't.

ELECTRICAL

Component Issue

Design Issue

-points closing up
-bad ground strap attachment to frame
-two generators puked up their guts
-dynamo definitely gave up
-lighting and wiring faults
-headlight connection fuse together

AXLE

Component Issue

Design Issue

-diff seizure (oil starved)
-axle shaft break (TR10)
-TR10 broke racing up steep hills
-rear axle leaks, some caused by flexing
-Cracks in the diff pan every few months

GEARBOX/DRIVELINE

Component Issue

Design Issue

-clutch thow out arm pin fell off during autocross
-prop shaft broken
-shocker journal - twice
-Stanpart remote gear shift bolts loosen

ENGINE - INTERNAL

Component Issue

Design Issue

-connecting rod let loose
-dropped a piston
-big ends and mains failure due to oil surge
-poor hardening of A2 cam
-two broken compression rings
-all valve guides needed to be replaced

ENGINE - ANCILLIARY

Component Issue

Design Issue

-knocked out the sump 3 times
-sump replaced once
-holed oil pan (2x)
-throttle cable seized
-starter engagement problems
-throttle cable seperated from the throttle pedal
-cracked mount on muffler

ENGINE - FUEL SYSTEM

Component Issue

Design Issue

-WEBER mounting nuts loosen
-run out of fuel
-clogged fuel filter
-fouled spark plugs
-stuck float in carb once
-SU carburators that tended to overheat

ENGINE - COOLING SYSTEM

Component Issue

Design Issue

-water pump failure
-water pump x 2
-overheating in slow traffic anytime of year
-leaking radiator hose
-head gasket blew
-radiator blew a plug twice
-multiple leaks and radiator problems
-swirl pot fell apart due to rust
-cracked swirl pot
-swirl pot cracks
-leaking swirl pot
-swirl pot rusting out

CHASSIS

Component Issue

Design Issue

-bad bushing on right motor mount and trans mount -twisted out n/s radius arm
-cracks/splits around the front suspension cross members
-distorted/twisted front A arm mounts
-failure in the tube where the rear radius arm connects from the rear axle (the joint where the top of that tube mates with the chassis was never welded from the factory)
-frame tube where curved tube meets cockpit side cracked 3/4 way round
-hundreds of loose/failed rivets
-dropped steering rack frame mounts
-broken motor mount
-rear trans mount barely connected to car

SUSPENSION

Component Issue

Design Issue

-broken front spring -rear a-frame break on the road
(this made the handling very sloppy, but it was still driveable -- at the top of the A when one side "disengaged" from the bushing holder)
-sway bar aluminum mount split
-broken bottom wishbone - rotted out from the inside

BRAKES

Component Issue

Design Issue

-brake cylinder right rear wheel leaked
-hard brake line rear axle sprung a leak
-front caliper froze

OVERVIEW

Component Issue

Design Issue

38 items reported.
Most common: Oil Pan, 6x
Second most common: Water Pump, 3x
Most problematic system: Cooling System, 9x
25 items reported.
Most common: Swirlpot cracks/rust, 5x
Second most common: T10 Axle cracks/leaks, 3x
Most problematic area: Chassis (surprise!), 9x

CURRENT CONCLUSION

Component Issue

Design Issue

Other than a few specific component failures, the majority of the component failures appear to have been avoidable via regular inspection and maintenance -- that and not bottoming one's oil sump! No surprise to the well versed Lotus Seven owner eh? Swirlpot, T10 Axle and Chassis frame are probably the three best known problem areas, and those weaknesses are illustrated by this review. Of course those of us blessed with BMC powered cars have fewer of these issues, and none a'tall of the swirlpot issues (Swirlpot?? What's a swirlpot?!).

So the Grand Total reported failures is 38 that are not necessarily the Seven's fault, and 25 that are. Many of the 25 that are could easily be attributed to the fact that the cars are simply being run long beyond their anticipated lifespan -- stuff gets old, stuff breaks! The 'non-Design' issues are more prevelant than the design issues. Unless the non-Lotus components are to be called 'underengineered and poorly designed', then we could in fact say that the Lotus designed bits have generally outlived the non-Lotus bits eh? By a ratio of 1.5 to 1 in fact! --And that's under hard use, well past the expected lifespan, and even most probably when pushed to the extreme with stickier rubber and multiples (2x, 3x 4x???) of the horsepower that Lotus ever anticipated would be let loose on their lightweight design! Think about it in that light, the cars are downright incredible!

My final word? The Lotus Seven, when used as intended, is a plain, no nonsense, efficient and highly durable machine whose main failings are those of the outsourced components, closely followed by the failing of their owners to properly maintain them. And lest I cast the first stone, I'm the one responsiible for fouled plugs (too eager to wait ofr it to warm up, so run with choke on... too long), radiator leaks (I put the wrong radiator cap on which simply did not allow ANY pressure to vent), clogged fuel filter (gotta clean that tank!) adn yes, even running out of gas (now I have a spare gallon can with me!)

Comments?

--John Donohoe 1 May, 2006

SimpleSevens.org