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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
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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.
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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
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SimpleSevens.org
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