Buckland found and interviewed an upholstery shop to replace the cracked crash pad and begin redoing the seats. Following Buckland’s checklist, a new soft-top was ordered along with new windshield and the associated mounting rubber surrounds for it. Other projects included:
- Heater box: Dismantling, cleaning, painting and rebuilding the electric motor in the heater box.
- Windows: Restoring the electric windows in the doors. Replacing all old cables with new, all new pulleys. Replacing all the cable guides. The motors were disassembled, brushes checked, cleaned, reassembled and painted. New felt strips went in all windows.
- Top frame: Cleaning, bead blasting and powder coating the frames that hold the soft top up.
- Gas Tank: Inspection of the gas tank, inside and out, to ensure no rust. There was none. The gas tank had been replaced a few years ago with a new OEM gas tank. The gas tank was repainted.
- Brake lines: After cleaning them, all original brake lines went back on the chassis. On close examination it was observed that the nuts on the brake lines had never had a wrench on them in 40 years. Photographs of the original routing helped in reassembly. The brakes got new pads.
- Drive shaft and Yoke: The drive shaft had some scarring. To ensure it would not leak oil a repair sleeve was installed for the drive shaft yoke.
- A Lumenition Magnetronic Ignition Module was installed. This fits inside the current distributor and retains the original look, but eliminates the points and condenser resulting in more reliable triggering of the spark. A fast charging/discharging capacitor allows for a stronger spark, meaning more complete burning of the fuel, less mis-firing, less hiccups at low RPMs as it puts out multiple sparks to the plug, not just one.
- The old, cheap, plastic fuel line was replaced with a 3/8 inch heavy duty aluminum one.
- Radiator: The old radiator was taken to a radiator fabricator (Commercial Radiator Service, Inc. on West McDowell Road in Phoenix) and used as a blueprint for a new radiator that will keep the Elan cool in hot Arizona and still fit in the front of the Elan. Then a set of high-speed racing fans were added to ensure maximum air flow.
- Generator: A replacement for the stock Lotus Generator is the 4.8 lb. Nippon Densu Alternator. It puts out 62 watts as compared to the stock generator that weighed 20 lbs. and put out 19 watts. This alternator is a favorite of aircraft builders, although it was first noticed on a Penske Formula 1 race car.
Next: Engine Process