Other Lotus Projects
Zetec Conversion for a TC
I am converting a TC a Zetec engine and NG transaxle. Other modifications include a cable shifter, hydraulic clutch, 4 40mm throttle bodies with fuel injection and a Mega Squirt programmable ECU. The final touch is restoring the body and painting it British Racing Green.
The starting point is to get a baseline of the very strong TC engine. The engine has Claudius headers and excellent running Strombergs and a electronic ignition. I estimate the 0-60 to be near 7~8 sec.
Here is the dyno results. 83 RWHP. Which would tend to validate the 105 claimed factory HP.
And clip on yellow box to see
video
As soon as the dyno was completed I pulled the motor and positioned the Zetec engine. Using the lift makes pulling the engine a snap. Once the engine is disconnected, lower the car, drop the engine 8" to the cart with the cherry picker, and then lift the car up. Then wheel the engine out. Roll new engine in.
Now comes the fun of making all the mounts.
Lotus engine by CLAUDIUS!
Here is a test spray of the new color.
Zetec Install proceeds -getting close....
2.0 Zetec W 60k. Individual throttle bodies, fuel injection, Mega-Squirt Programmable ECU, Ford racing headers, NG transaxle, Zetec flywheel and starter, custom cable shifter, Toyota alternator.
Top view with throttle bodies and Zetec injectors, modified rail. and alternator barely visible You can see the idler arm bracket and alternator mount.
Here is a comparison of the NG vs the 336 transaxle. You can see the difference between the stubs.
Cable shifter- heavily modified Celica shifter, that will come apart in order to insert into frame. Next is the shifter in frame - everything fit through that small hole, and the end result. Then MegaSquirt parts
Custom brackets for fuel pump & filter, exhaust system, and Zetec with MegaSquirt, exhaust, throttle bodies, remote oil, and headers
The body has a ton of stress cracks.
And the finished product
Here is a short summary of the components and engineering. (I'm sure I missed some stuff)
Components
2.0 Zetec engine
NG Transaxle
GSX individual throttle bodies
Megasquirt (MS) ECU & relay board
Cable shifter
Toyota Alternator
Zetec Starter/flywheel/pressure plate
2”OD muffler
Ford Racing header
Ford EDIS
TC bell housing
Ford 200 EFI fuel pump
Lucas pressure regulator
Custom fuel rail
Ford fuel injectors
EFI fuel filter
Weber air cleaners
Ford & GM sensors
Engineering
Motor mounts
Alternator mounting
Idler arm bracket
Modifing engine girdle for starter
Starter mounting
Rear transaxle brackets
Rear frame support and crossmember
Exhaust system with collector,
Exhaust o2 bung, and rubber mounts
Throttle cable mounting
Adapting ITB to intake
Air cleaners customized
Assemble MS ECU, cabling
Assemble MS relay board
MS sensors
Cable shifter mechanism
Frame modified for cable mechanism
Cable mechanism
Cable transaxle mounts
Clutch cable mount
Coolant plumbing
Water pump outlet welded
Main shaft bearing for bell housing
Bell housing welded for strength
Bell housing machined for clearance