Roundel mount patch

As I worked on getting the Lotus ready for last week's show I started a list of a the little things it needs. Turned out to be a pretty long list. I decided to try taking the Lotus to the shop on Sundays and knocking off a few at a time as I work on the E9, but before I do that I want to improve its starting. Currently it only cranks from the booster battery, and when the engine is hot even the booster has a hard time getting it going. Funny thing is, once it starts to crank it turns very fast. I already changed out the original starter with a Denso reduction gear model from Dave Bean (see photos). I brought home my toolbox today and plan on checking all of the grounds in the starting circuit. I don't think it's heat from the headers, because it also happens, to a lesser extent, from a cold start.

Today was just a continuation of the E9 nose job, which has progressed to the roundel mount. I hand formed one several months ago and since it turned out better than expected I decided to use it. To get started I had to measure everything very carefully and come up with a way to position the patch after the original is removed. In the process I discovered that the existing mount is offset to the right (to the left in the photos, which are upside down), about 1/8 in.

After getting the alignment worked out and a rough cut on the rear edge it was time to put some bend in the patch. This does not need to be perfect, just good enough to slip under the existing good metal. For this I held it in the vise and whacked it with a hammer on a hardwood block, moving 1/8 in. at a time, then a little smoothing witha convex faced hammer on a sand bag.

Finally the time had come to cut away the old roundel mount. A bit nerve racking, because I had to be able to position the replacement without it. With the rusty pieces removed I went in with tapered and straight file tips in the die grinder to remove a few damaged places underneath and the smooth out the cut edges.

I finally got to where I could slide on side underneath, so that I have a better feel for how this will end up. Not sure which side will get cut down, maybe both. It's good to sleep on it. I finished by giving everything a fresh coat of Metal Prep.