19

As you get further back, the bolts will get harder to undo, because there will be less engine and gearbox oil around. These next two mounting points are just behind the gearbox cross member.

 20

The next pair of body mounts to be undone are further back along the chassis rails, just ahead of the differential. Take your time because it's easy to  round off these mounting bolts.

 21

The last of the body mounts are at the rear end of the chassis. They're just below the battery tray, so are often seriously corroded from battery acid. If you really have to, then grind the heads off these bolts.

22

Back inside the car you'll find two bolts attaching the base of the dashboard to the transmission tunnel. They go through to the chassis, so you'll have to undo them before the body can come off.

23

You'll find two bolts on the rear bulkhead, on the interior (not boot) side. The bolts go through to the chassis rear suspension turrets. Undo these - now the body should be free of the chassis.

24

Unless you have the use of a hydraulic lift, strip out the glass and unbolt the doors to lighten the body enough for four blokes to lift off. We cut the glass out. Next issue we'll lift off the body.

PROJECT PROFILE

THE PLUS 2 was the Lotus company's attempt to build on the success of the two-seater Elan, by adding rear seats and a few luxurious touches. The backbone chassis of the Elan was lengthened and the glassfibre body was all-new.

The new model emerged in 1967 and sold well. However, it's never been as popular as the two-seater Elan and many have been abandoned as beyond economic repair, even though the bodies are usually still good.  Spyder's Zetec conversion addresses this, being cheaper than a restoration to original specifications.  The resulting car is also significantly faster, more reliable and better to drive.

Our car had been laid up for years, with a rotten chassis and worn mechanicals. 

COSTS SO FAR

Car: £1000 (£1600 purchase, minus £600 for parts sold)

PLANNED INSTALLMENTS

Part 1: preparing to remove body
Part 2: stripping body and chassis
Part 3: building new chassis
Part 4: converting and installing engine
Part 5: repairing and painting body 
Part 6: putting it back together

SAMPLE SPYDER CONVERSION PARTS
Spaceframe chassis: £1875
Rear disc conversion: £1081
Front disc/ball-joint conversion: £1110
Steering rack conversion: £276
Zetec mounting brackets: £112
Differential mounting brackets: £112
Driveshatfs (pair): £223
Anti-roll bar kit: £223
Propshaft: £164.50
Gearlever kit: £229
Engine/gearbox isolators: £41
Differential isolators: £94
Gearbox output flange & bolts: £66
Handbrake lever and cables: £135
Brake hose kit: £47
(All prices include VAT)
JOIN THE CLUB: Club Lotus, Lotus Drivers Club (see Club Guide, page 174)
READ THE BOOK: Lotus Elan, the Complete Story, by Mike Taylor.  Crowood. ISBN 1 86126 011 3.
WHO'S INVOLVED: Spyder Engineering is a fabrication company, specialising in automotive work.  The Lotus connection came about in the mid-Seventies, when the demand for replacement Elan chassis outstripped the Lotus factory's supply.  Spyder improved upon the design, with a spaceframe-type design and the option of an upper rear wishbone to improve strut location.

The company later developed chassis for other Lotus models.  The Spyder chassis (for Elan and Plus 2) will now accommodate the original Twin-Cam or the Zetec, and the original four- or five-speed gearboxes, or a modern Ford five-speeder.

Spyder is in Whittlesey, Cambridgeshire.  Call 01733 203986 or 205639 or go to the website www.spydercars.com. 

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PRACTICAL CLASSICS FEBRUARY 2003