After a long hiatus, I finally have something to say.
Regular readers will recall that my spring trip last year began on a sour note when my car was backed into in the motel parking lot. After much back-and-forth with the insurance company, they cut me a check. Actually, it was two checks. Even though I got photos of the license and insurance cards of the other party, it took AllState nearly seven months to get my deductible back.
They paid “enough” to have my front clam replaced with new. It’s never that simple, though. I understand that replacement clams require a fair amount of work to make them fit properly. I have little doubt that, if I had gone that route, it would have cost more than AllState’s estimate, no doubt requiring additional months for payment. It would have all worked out in the end, no doubt. But I went another way.
I discussed it with Mike G., and he made me a proposal. He had recently purchased an Elise that needed repairs to its front clam. He said that if I bought all the supplies and materials to repair both clams, he’d do all the work. This would save me a considerable amount of money.
He knew, too, that I was having third gear syncro issues (again). He offered to do the transmission swap for me. The plan was to replace the transmission and repair and repaint the clam, have it done by autumn and maybe have a few hundred dollars of the insurance money left over. It’s spring, not autumn, and the table below shows that I blew through the budget. That’s due to the bits Mike and I didn’t talk about: PPF and the yellow stripe. And, frankly, it’s a killer deal. For less than a thousand dollars, my 111,000 mile, 75 track day car looks better than it has in a decade.
I picked up a rebuilt transmission with the Celica sixth gear. It’s a Toyota C64 transmission. Lotus uses a different sixth gear than Toyota used in the Celica. With the Celica sixth gear, I’d get improved fuel economy on the highway. While we were swapping out the transmission, I took the opportunity to upgrade the shifter cables and replace the clutch.
Mike also kindly let me borrow a spare front clam that he had. This allowed me to continue driving the car while he repaired and repainted the clam. So I drove around for a couple of months with an orange front end. It was not pretty, but it beats leaving it parked in the garage.
The car had a paint protection film (PPF). I believe it was applied at the Lotus factory, but I’m not certain. It’s not mentioned on the price sticker. I can’t imagine that, if it was done by the selling dealer, it wouldn’t have shown up as a dealer-installed option, but I’d also expect it to be called out on the list of standard features. In any event, it had PPF. After Mike repaired the clam, I’d have to get PPF applied to it. This sort of led me down a rabbit hole.
One of Michael’s high school friends, Loren, is a car detailer and has applied PPF to all sorts of exotic cars, including Ferraris and Lamborghinis. After chatting with him a couple of times, I decided to redo the PPF for the whole car (not just the front clam) and get the windows tinted. He also recommended a protective film for the windshield. This film isn’t a magic bullet that will prevent all damage – big stones will still cause some damage – but the normal, run-of-the-mill damage we get driving Colorado’s roads in the winter will be prevented. The last of Loren’s jobs was to replace my yellow stripe. It was impossible to match the color and just do the bit of stripe on the clam, so we redid the whole stripe.
In addition to these three big jobs – clam repair, transmission swap, and PPF application – I took the opportunity to make some minor changes. The black body parts – grill pieces and louvers – were looking tired and needed some attention. The car is so low, I often scrape the nose entering or leaving parking lots, so Loren found a product that may protect the fiberglass. The rear-view mirror is too big, so I finally found a smaller replacement. And, finally, even though the car is brightly colored and somewhat loud, I find myself having to use my horn to let people know I’m there. The stock horn isn’t very loud. Rather than replacing it with a louder one, I left the stock one in and added a louder one (Harley-Davidson’s “Loud” horn). I often joked I wanted an air horn from a railroad locomotive. This one isn’t that loud, but it’s loud.
When I brought the car home from Mike’s, we didn’t put it all together right away. It was easier for Loren to apply the PPF without the headlights, turn signals, and trim pieces installed.
The transmission swap was last summer, before my trip to LOG. There I had overheating problems. It was fine on the roads, but after about twenty minutes on the track, I’d sometimes be unable to get it into any gear. After asking around, one of the suggestions was to use a different gear oil. So, while the car was out of commission waiting for the PPF to get done, I replaced the gear oil.
The expected life of PPF is five to ten years. The original PPF was going on twenty. The old film came off pretty easily with steam. I’ve heard horror stories of removing old film, but the car has been garaged its whole life and I think that made a big difference. The film was pretty beat up – scratched, pitted, and discolored – with the worst damage on the sills just in front of the rear wheels.
Applying the PPF, Loren got detailed look at the paint. It was still near perfect. Given what I subjected my poor car to, it says volumes about the value of the PPF. Loren also said Mike did an excellent job, especially considering he did the paint in his garage. The paint isn’t a perfect match, but pretty damn close.
New, the car had PPF on the front clam only covered the front half. I now have it over the entire clam, including the removable panels. This is 8 mil film. On the sills, we went with 10 mil for better protection.
We did a ceramic coating on the PPF. Loren wanted to do a side-by-side comparison of two different products, but that didn’t work out. The film, made by Stek, only accepted their ceramic coating. Loren’s usual brand wouldn’t go on properly.
Before applying the bumper scrape guard, by Sliplo, Loren added another layer of PPF on the bottom of the clam. The Sliplo product is attached with a provided two-sided tape, which comes with an adhesive promoter. This allows it to stick quite nicely to the PPF.
I had to restripe the whole car. It was pretty much impossible for us to match the color. The new yellow is a tad brighter, but you can only tell the difference side-by-side. It, too, came off fairly easily with steam.
Replacing the rear-view mirror gave me a bit of heartburn. It’s quite common for people to break their windshields trying to get the stock mirror off the plinth, which is attached to the windshield. In my case, the whole thing came free. I replaced the windshield last year; no doubt the adhesive was a bit different than stock. The mirror was quite reluctant to come free from the plinth. They had used some sort of adhesive, which seems unnecessary to me. We had to clamp the plinth in the vise and persuade the mirror gently with a mallet. If you couldn’t get the whole assembly off the windshield, it’s no wonder people were breaking their windshields. The smaller mirror blocks much less of my forward vision and is plenty big enough to see out the back window. I didn’t weigh them to compare, but the MicroMirror felt a few ounces heavier.
The whole process took a bit longer than I’d hoped, but I’m quite happy overall. Both Mike G. and Loren did a great job. I still need to figure out the shifting problem, but I have no doubt I’ll get it figured out eventually. The car has over 111,000 miles on it and looks as good as it did when I bought it. And, as a bonus, I expect to get over 40mpg on road trips (I’ve already had one at 39.5).
I’m looking forward to the next hundred thousand miles!
Cost Breakdown | Amount |
---|---|
Clam repair/repaint | $2,568 |
PPF | 1,100 |
Window Tint | 150 |
Lip Protection | 150 |
Windshield Film | 300 |
Stripe | 200 |
Ceramic coat | 100 |
Badge | 110 |
Transmission | 3,849 |
Cables | 686 |
Clutch | 470 |
Gear Oil (Motul) | 41 |
Horn | 71 |
Black spray paint | 7 |
Gear Oil (Red Line) | 22 |
Total Cost | $9,824 |
Insurance Claim | $9,043 |
Out-of-Pocket Cost | $781 |
Naturally, I made videos of Loren working his magic.