Cosworth powered Group4 Lotus sunbeam

 

Although I'm a Ford fan myself I have always had a soft spot for the old Lotus Sunbeams. My brother and fellow Motorsport enthusiast, had owned LTT 646W for 14 years and was one if not the best Lotus Sunbeam in existence. This car had won numerous concourse days in both class specific and general classic shows. The time had come when although concourse is lovely to see, the longing for a FAST Lotus track car was too great.

The first task was preparing the shell. The car was stripped to a bare shell, and the front and rear arches modified to take Gp4 arches. The next addition was a set of Bilstein 2 ¼" coil over units coupled with AP four pot calipers and 260mm alloy bell grooved/vented discs up front, whilst the rear uses Sierra cosworth calipers and mk3 escort front discs. These discs were limited in size due to the wheel size choice. 10X13" for the rear and 8X13" for the front. The car is also fitted with a fly-off hydraulic handbrake and plumbed extinguisher system.

The next step was to fit the multipoint weld in cage. This was installed to MSN regulations with the necessary foot plates welded to the shell. The cage was fabricated to pass through the front bulkhead picking up from the front struts, whilst the rear sections pick up off the rear suspension pivot points to give an extremely stiff shell. Interior has been limited to carbon buckets, and an alloy dash, along with Perspex windows, all in an attempt to reduce weight.  The rear panel of the body work beneath the bumper has been removed exposing the rear axle and suspension and removing weight. The rear axle is a braced atlas unit with fully floating thick quaife half shafts and a ZF plated LSD and the 4 links are nylon bushed. Gearbox selection in a Borg Warner based unit.

In the engine bay, a new bulk head was fabricating allowing the engine to be moved rearward by  4 inches. The engine required a special sump to be fabricated to clear the cross member and allowed the engine to be lowered as much as possible in the engine bay. The fuel tank was moved in car and is housed in a seal unit along with two lift fuel pumps and a swirl pot feeding a Bosch 044 roller vane pump. The main tank is fed from a filler housed in the rear Qtr window.

Up front the tie bars and TCA's are fully adjustable rose jointed affairs  to allow adjustment to both caster and camber, whilst a revised steering rack position has improved bump steer.

Inside the car a fly-off hydraulic hand brake is used, a plumbed in fire extinguisher system is present and the dashboard houses only necessary gauges and switches, the majority of the car having been stripped/removed/cut out to remove excess weight.

Up front the new cosworth power unit has been developed for maximum torque and response. The specification is extensive but maintains a Garrett T34 turbo in order to give a wide on boost power band of of 3200rpm to the 7600rpm limit. We have mapped the cars on greys and uses one of our triple cosworth intercoolers.

This car has been competing for two years now in numerous speed and hill climb championships around the country, with occasional visits to santa pod and various race circuits for "fun" track days. Our current best Qtr time is 12.2@120mph at Santpod.

 

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