Front strut suspension washer failure                     

This diagram from the Lotus Service manual clearly shows the washer seated right up into the

mount with no gap between it or the tube, also noted is just how much the walls of the mount 

taper inwards, after much discussion with other club members I've decided to modify the thicker 

washers so that they fit better into the mount and minimise the gap before the clamp nuts are 

tightened down. It's also clear from the diagram that lotus wanted to remove all vertical upwards 

flex in the mount from the shock rod.

 

The current washers are 62mm outside diameter, I reduced this to 59.5mm and retained the radius 

profile, and added a small radius to the outer edge which faces the bearing

 

Below shows again a new mount with the old washer and un-modified washer in place.

 

This picture shows the modified new washer in place, there is only about 1mm gap now.

Not only that but it looks a better job too.

Old washer tight within bearing                               New modified washer with clearance.

The old washer does actually fit through the bearing with a gentle push. 

Right, I'm happy with this compromise, now it's all back together I look forward to March1 2005 when it 

goes back on the road ;-).......but not so soon........I need to reset the camber then tracking

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