LSB2468 - even numbers for an odd car

[SENC]

I checked and do have a 2nd copy of the Dave Bean catalog.

 

Unfortunately, there isn't anything useful for your Seven specific to the rear suspension, but you may find other sections (like front suspension and gearbox) useful.  If you'd like it, pm me your name, address, and number and I'll get a cost for shipping it to you.

 

There is another Bean catalog worth keeping an eye open for:

 

 

One of these days I'll get around to having it scanned to add as a resource.

[Darcy]

48 minutes ago, EdWills said:

so just under 1/4 inch thick

@EdWills Thanks for doing that.  I'll aim for 1/4".  Chris has made a number of great comments in the FB thread.  I think it would be prohibitively expensive to send it down to the US, so I think I will do my best to add the 1/4" plate - very slowly with minimum heat.  I will probably make up some kind of measuring method so I can see if the axle is deflecting at all during the tacking process.  I have no intention of driving this like a modern Caterham, so I think if I can stabilize it, it will be ok.  If I want a thrill I will jump on my KTM 1290 Superduke.  It has 173HP and weighs about 425lbs.  That bike makes your eyes go wide in a hurry. 

Edited September 15 by Darcy

[SENC]

Here's an alternative solution a prior owner of my car implemented.

 

[IamScotticus]

On 9/13/2026 at 9:59 AM, Darcy said:

That's good information.  I never thought about pulling the axles out before removing the full assembly, but that would make it lighter, and easier to work on while removing the brakes etc.  

I'm having trouble finding good information on the Escort axle - how to disassemble, check, and reassemble correctly.  

there are Haynes manuals for Mk1 Escort.  if you need page shots, PM me.   Don't start banging on anything until you know the correct process.  Ask me how I know..

[EdWills]

12 hours ago, IamScotticus said:

there are Haynes manuals for Mk1 Escort.  if you need page shots, PM me.   Don't start banging on anything until you know the correct process.  Ask me how I know..

And Darcy, it is a good idea to mark which side the axles came from.  In the heat of battle, it is easy to swap them.  Advice from a Haynes manual.  Cheers, W.

[Darcy]

Making progress.  I found a company in the UK that makes braces for Ford rear ends.  Someone posted a picture of their products on the Lotus 7 Facebook page and I found the company:  www.retroford.co.uk

I cleaned up the rear end and welded them on.  I did it slowly with small tacks, then larger welds spread all over the axle.  Air cooled with compressed air after each weld to get the temperature down.  I'm an amateur welder but I think they will hold.  

The car only has 22,000 miles so I was expecting the gears to be in good shape.  Everything looked good. I noticed some interesting marks on the gears in the differential.  Anyone know what they mean?  

Edited Friday at 05:08 PM by Darcy
Added URL for Retroford

[IamScotticus]

Will you baffle the case?  They are walls at the entrances of the tubes to keep oil from collecting at the ends during extended cornering, unless your end bearings are case oil lubricated, but I don't think that is common.  

 

Another mod is to tap in grease zerks to feed the outter bearings, if they are grease lubricated.  This may involve making a hole into the bearing race.  I don't know the particulars of doing this, but it will simplify maintenance.

[Darcy]

I did see the plates to prevent oil sloshing into the tubes. The bearings appear to be sealed, so I don’t think I will be drilling holes in them. Too risky. This thing is not going to be raced at Goodwood. I just need it to be oil tight and safe. 

[Darcy]

I need to find replacements for the bushings at the bottom shock mounts. Are these available?

[IamScotticus]

some fine fellows at Jack Webb, They know this stuff as they specialize in LA Sevens, and have the best dampers $$$.  although I'm sure adjustable SPAX G978 or GAZ GP6-2037 will do.

however I believe what Webb and others have found to benefit the LA rhe most is are spherical bearings on the lower damper mounts.  this will go a long way in keeping the bampers straight and not rubbing on the springs.  

to replace the bushes on your dampers you have to press out the bushes and replace.  I think the efforts are better rewarded with sphericals spaced with nylon bushes.

 

gawd....I'm starting to sound like MV8....omg.  but he did have good contributions.

 

Anyway, here is a closeup of what JWM is doing.  you can see the sphericals encased in the lower stems, wirh spacer  sleeves held by zip-ties.

https://jackwebbmotorsport.co.uk/Caterham-Quantum-One-Zero-by-JWM-Road-Track-Live-Axle-Calibration-p613809851

Edited Saturday at 03:02 AM by IamScotticus