Bodycare & repair
Contents
1. Dash baffle panel Demist air duct Face level vent duct Chassis scuttle Heater pipe b282b m Page 12 The shape of the frame is critical to the windscreen fit and structural repairs to the frame itself are not recommended It is not generally economic to attempt to remove the windscreen frame intact for refitment as the elastomeric adhesive bonding the frame to the chassis requires cutting with a reciprocating knife and access to the joints is sometimes obscured The recommended procedure is to cut the frame as necessary to allow its removal without damage to the dash baffle panel If the sills are to remain fitted it will be necessary to carry out some minor work on the screen buttress to sill panel joint where a panel overlap occurs To Replace Windscreen Frame 1 Remove the front wheelarch liners and front clamshell see sub section BR 5 and for improved access the two doors 2 Remove the windscreen see sub section BR 14 3 Remove the instrument binnacle and fascia top panel see sub section BR 13 and release the fixings between dash upper extrusion and screen frame 4 Release the brake hose pipe connector at the front end of each buttress on the windscreen frame Release all harnesses and other components from the windscreen frame buttresses as necessary 5 Remove the wiper motor mechanism from the windscreen frame 6 Use a sealant cutting tool to cut the bond between the windscreen frame buttr2. BODYCARE amp REPAIR SECTION BQ Sub Section Page General Description BQ 1 3 Lotus Composite Body Features BQ 2 3 Bodycare BQ 3 4 Accident Damage Assessment BQ 4 5 Body Panel Bonding Materials BQ 5 6 Replacement of Bonded On Panels General BQ 6 9 Front Crash Structure BQ 7 10 Windscreen Frame BQ 8 12 Sill Panels BQ 9 16 Rear Bulkhead BQ 10 17 Ie Body Panels Door shell Windscreen Sill panel Front access frame panel Engine cover lid Front clamshell Cabin rear bulkhead Door hinge cover panel Rear clamshell Front crash structure Chassis frame b277b BQ 1 GENERAL DESCRIPTION The body panels of the Lotus Elise are constructed of composite materials with the external panels not being required to contribute to chassis rigidity The panels are attached to the aluminium chassis and or other body panels either by elastomeric polyurethane adhesive or in the case of the front and rear clamshells are bolted on for ease of dis assembly and access to chassis parts The composite mouldings are manufactured by one of several processes see later dependent on application with a nominal thickness of 2 2 2 5 mm The windscreen frame incorporates foam beams to create closed box sections for optimum strength and a crash structure bonded to the front of the chassis incorporates longitudinal box sections to provide specific crush characteristics and absorb crash impact by progressive colla
3. Apply a second strip up each vertical face Prepare the old adhesive bead on the chassis for fitment of the windscreen frame by removing excess sealant from all the bonding areas on the chassis sill panels and dash baffle to leave a consistent and level bonding surface for the new frame It is not necessary to remove all traces of old adhesive but a uniform surface must be available for the new adhesive bead The remaining adhesive must be securely bonded and be cut with a scalpal blade to leave an even thickness of 1 2 mm Fit the wiper motor assembly and windscreen washer jets to the windscreen frame If necessary fit a new roof side rail latch plate to the windscreen header rail it is not recommended to refit a bracket due to the requirement for high surface quality on the bracket If applicable completely remove any old adhesive from the header rail taking care not to damage the com posite substrate Lightly abrade the bonding surface on the header rail but do not abrade the bracket Clean the bonding surfaces on the header rail and bracket with Betaclean 3900 see sub section BQ 5 Prime the header rail with Betaprime 5404 but do not prime the bracket Generously coat the bonding surface of the bracket with a 50 50 mix of Betamate 7064S A116B0159V and Betamate 7014 A116B0158V Fit the bracket to the header rail and wipe off extruded adhesive with Betaclean 3900 Position the bracket using tool TO00T1422F RH or TO00T142
4. a new assembly bonded into position The shape and positioning of the windscreen frame is crucial to the fit of the windscreen and sealing of the soft top roof such that the only repairs which should be considered for this panel are cosmetic and superficial any structural damage should entail panel replacement The sill panels include the A and B posts and involve much labour time to replace Localised repairs should be performed whenever possible although access to the inside surface of some parts of the panels is not freely available Note that if damage is such as to require replacement of the chassis replacement chassis assemblies are provided only as a partial body assembly which includes jig bonded front crash structure windscreen frame side sills and rear bulkhead The roof hoop and rear subframe are also included as are the pipes hoses and cables routed through the sills eS Page 5 O BQ 5 BODY PANEL BONDING MATERIALS The materials used for bonding the body panels are manufactured by Dow Chemical and in order to maintain the structural integrity of the vehicle and in the case of the front crash structure the safety it is most important to use only the specified materials The surface preparation and cleaning and priming operations are crucial to the performance of the adhesive and must be followed in detail The products to be used depend on the surface substrate onto which they are applied and the following
5. around the door hinge post and to the windscreen frame and smooth with a spatula Clamp the panel into position until the adhesive has cured see sub section BQ 5 If the top front corner of the sill flange has been cut to fit around the windscreen butress flange this area should be reinforced as follows Roughen the surface of the windscreen buttress flange and the adjacent sill panel in the modified area and lay up two pieces of chopped strand mat across the joint Refit the dash panel front and rear clamshells doors both wheelarch liners and other components as necessary BQ 10 REAR BULKHEAD The rear bulkhead is a Polyurethane Structural Reaction Injection Moulding PU SRIM incorporates the rear window surround and is bonded to the roll over bar and chassis fuel tank bay A heat formed polyester fibre heat acoustic insulator panel is bonded to the rear side of the panel and incorporates a glass fibre alu minised cloth heat reflector shield in the vicinity of the exhaust manifold The rear window is bonded directly to the bulkhead using the same materials and procedure as is used for the windscreen e a a A Page 17 ay To replace the rear bulkhead 1 Remove the rear clamshell see sub section BR 6 2 Remove both seats and the bulkhead interior trim panel 3 Remove from the inside of the bulkhead the microwave sensor and immobiliser module Release all wiring harnesses from the bulkhead clips 4 Release all f
6. list identifies each application Anodised aluminium e g chassis and components Cleaner Betawipe VP 04604 Lotus part no A082B6150V Primer Betapnme 5404 Lotus part no A082B6337V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Unpainted or painted composite Cleaner Betaclean 3900 Lotus part no A100B6008V Primer Betaprime 5404 Lotus part no A082B6337V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Zinc plated and passivated steel Cleaner Beatclean 3900 Lotus part no A100B6008V Primer Betaprime VP 01706 A B Lotus part no A100B6070V Adhesive Betaseal 1701 Lotus part no A082B6281F Glass Cleaner Betawipe VP 04604 Lotus part no A082B6150V Primer Betaprime 5001 Lotus part no A100B6009V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Uncoated Lexan Perspex Cleaner Abrasion amp dry wipe Primer Betapnme 5404 Lotus part no A082B6337V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Residual adhesive i e rebonding to surface after cutting off old panel Cleaner primer amp re activator Betawipe 4000 Lotus part no A082B6355V Adhesive Betaseal 1701 Lotus part no A082B6281 F or Betamate E2400 Lotus part no A082B8415V Applicator Bottle An applicator bottle is available for use with some cleaners and primers and has a
7. lukewarm water together with a proprietary car wash additive household detergent and washing up liquid can contain corrosive salts and will remove wax and accelerate oxidation Frequent washing is the best safeguard against both seen and invisible contaminants Wash in the shade and use a cotton chenille wash mitt or a sponge rinsed frequently to minimise entrapment of dirt particles Use a straight back and forth washing motion to avoid swirled micro scratches and rinse thoroughly In order to minimise degradation from road salt the underside of the chassis should be rinsed with clean water as soon as possible after driving on treated roads Many fuel filling stations offer pressure washing facili ties ideal for this purpose but to not use on the painted bodywork or soft top roof Soft Top Roof 1 Careful vacuuming of the soft top before washing may be helpful in removing excess dust and other foreign particles 2 Wash in partial shade rather than strong sunlight and wet the whole car before tackling the soft top 3 Using only clean lukewarm water and a sponge a chamois or cloth will leave lint and a brush may abrade the threads wash the entire top uniformly Do NOT use a detergent which may affect the waterproofing properties of the material Rinse the whole car to remove all soap from the fabric and to prevent streaking on the car bodywork Remove surface water with a sponge and allow to air dry in direct sunlight Ensure that
8. seconds to disperse the solid content of the material into suspension Pour the primer into the applicator bottle and immediately replace the green cap Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides Wipe the pad over the activated cleaned substrate surface to apply a continuous film of primer Allow to dry for a minimum of 15 minutes before applying adhesive If adhesive is not applied with 72 hours wipe on wipe off with Betawipe VP 04604 The appearance of the primed areas should be deep black in colour with no streaks or voids To achieve this appearance apply in smooth continuous uni directional movement not short backward and forward movements The latter technique results in inconsistent film build Rework any poor areas after 5 minutes tack time applying in the same direction Replace the felt pad if moisture absorption results in hardening Never return unused Betaprime back into the aluminium container eS Page 7 ay BETAPRIME 5404 A082B6337V Description Application Notes Adhesion promotor used to maximise the performance of the bonding between the cleaned and or activated surface and the adhesive compound Supplied in 250 ml aluminium container with RED coloured cap Two steel balls inside the container are provided to assist mixing of the contents when shaken Prior to decanting Betaprime 5404 shake the container for at least 60 seconds to disperse t
9. ventilation cannot be provided storage outside on a hard standing or under a carport is to be preferred BQ 4 ACCIDENT DAMAGE ASSESSMENT The repair method to be employed in the rectification of accident damage to composite panels is to be assessed reletive to the particular panel and its method of attachment Bolt on Panels Front Clamshell Rear Clamshell Door Shells Front Body Access Panels Engine Cover Lid Door Hinge Cover Panels Rear Window Shroud Hard Top Roof These panels are secured by threaded fasteners and are easily removed for access to the back of any damaged area for repair by conventional composite techniques Instructions for the removal and refitment of these panels are contained in section BR Bonded on Panels Windscreen Frame LH amp RH Sill Panels Front Crash Structure Rear Bulkhead These panels are bonded to the chassis or to other panels using a flexible polyurethane adhesive which must be cut before the panel may be removed In some cases it may be necessary to partially remove another panel before the subject panel can be released It is not generally economic to attempt to remove a bonded panel intact for later re fitment The integrity of the front crash structure is crucial to the safety of the car in a frontal collision and it is rec ommended not to attempt any major repair of this component The damaged structure should be cut from the front of the chassis and
10. 3F LH which sould be taped to the header rail for at least 30 minutes Before fitting the windscreen frame ensure that two setting rods are available for positioning the frame Cut two 670mm lengths of locally sourced 10mm diameter steel rod Prepare and re activate the old adhesive bead on the chassis using Betawipe 4000 see BQ 5 Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime 5404 see sub section BQ 5 Apply a bead of Betaseal mate adhesive see sub section BQ 5 to the whole of the bonding flange on the windscreen frame and butresses including the mating face between frame underside and baffle panel Carefully fit the windscreen frame onto the chassis and press into position to ensure adequate adhesive compression Ensure the frame is positioned correctly in relation to the roll over bar by fitting the two set ting rods in the roof siderail locating slots The rods should locate snugly in the slots with no end play Clamp the frame into position until the adhesive cures Ensure good adhesion between the frame and baffle panel Use a spatula to smooth out or remove any excess or extruded adhesive Seal the frame panel to the top of the door hinge post at each side by extruding a bead of Betaseal and smoothing with a spatula to obtain a neat finish Examine the whole of the bonding jointline for sealing integrity and if necessary apply additional adhesive to seal any gap
11. d a vibrating action This tool may also be used to remove windscreens Supplier Chicago Pneumatic Utica New York 13501 USA Catalogue no CP838 Pneu Nife Recommended air pressure 60 90 PSIG 4 0 6 2 bar Tool air inlet 1 4 NPTF 3 8 mm hose size eS Page 9 E Operating handle Compressed air inlet Vibrating cutting blade It is not generally practical to remove a bonded panel intact for later refitment Consequently when necessary the panel can be cut away for better access to the bonded joint It is not necessary to remove all traces of sealant from the joint faces on the remaining panels or chassis but any remaining sealant must be securely bonded and no thicker than 1 mm or the fit and joint gaps will be upset It is essential always to follow the cleaning priming bonding operations meticulously if sufficiently strong and durable bonds are to be obtained Always use the specified materials BQ 7 FRONT CRASH STRUCTURE The front crash structure consists of an upper and lower moulding bonded together and supplied only as an assembly It is bonded to the front face of the chassis and is braced by an alloy undershield screwed to the bottom front edge of the chassis and to each lower side of the crash structure The unit also acts as a ducting for the engine cooling radiator and a c condenser if fitted which are mounted horizontally on its top surface in a bolted on composite radiator housing Longitudi
12. disposable felt pad which should be changed regularly to minimise surface contamination Applicator bottle A000Z1071F Cap A082B6353S Felt pad A082B6354S Product Usage BETAWIPE VP 04604 A082B6150V Description Activator and cleaning agent used to promote adhesion to the substrate surface Supplied in a 250ml aluminium container with a YELLOW coloured cap Application Wipe on wipe off type Pour Betawipe VP 04604 into applicator bottle and immediately refit the yellow cap onto the container m PA 6 Notes Push the applicator head onto the bottle and fit the felt pad Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides Wipe the pad over the substrate surface using minimal pressure to wet the surface Immediately wipe off the activated cleaned surface using a clean fibre free cloth and dis card If the substrate is very dirty first wipe off the surface with a clean fibre free cloth and dis card Do not leave the caps off Betawipe containers A milky colour indicates moisture absorption and the material should be discarded Only decant a sufficient quantity of Betawipe for the job concerned and never pour material back into the container from the applicator bottle Change the felt pad at regular intervals to reduce surface contamination BETACLEAN 3900 A100B6008V Description Application Degreaser and cleaning agent used for the removal of conta
13. esses and chassis and between the frame and B posts and between the frame underside and dash baffle panel Remove the windscreen frame 7 Cut the adhesive securing the drainage gutter around the front of the frame to allow transfer to the new frame 8 Ifthe dash baffle panel is to be replaced the clutch pipe and climate control cables must be released and threaded through the panel before cutting the adhesive Primer band on chassis Heater pipe grommet Primer band on baffle Sa RSS N EEN Dash baffle panel Foam strip 7 sr Page 13 mmu 10 11 12 13 14 15 16 17 18 To fit a new dash baffle Ensure the heater feed and return pipes are fitted Dry fit the panel and mark up the bonding surface on the chassis scuttle Prepare and re activate the surface of the old adhesive on the chassis using Betawipe 4000 see BQ 5 Clean and prime the upper and lower bonding faces on the new baffle panel using Betaclean 3900 and Betaprime 5404 see sub section BQ 5 Apply a bead of Betaseal mate adhesive see sub section BQ 5 to the baffle lower flange Position the panel and press along the length of the joint to ensure sufficient spread of adhesive Clamp the panel in position until the adhesive cures Apply self adhesive foam strip AO82U6065V to each vertical end face of the baffle panel wrapping over onto the top edge and along to the primed surface
14. he solid content of the material into suspension Pour the primer into the applicator bottle and immediately replace the green cap Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides Wipe the pad over the activated cleaned substrate surface to apply a continuous film of primer Allow to dry for a minimum of 15 minutes before applying adhesive If adhesive is not applied with 24 hours re activate by applying a further coat of Betaprime 5404 The appearance of the primed areas should be deep black in colour with no streaks or voids To achieve this appearance apply in smooth continuous uni directional movement not short backward and forward movements The latter technique results in inconsistent film build Rework any poor areas after 5 minutes tack time applying in the same direction Replace the felt pad if moisture absorption results in hardening Never return unused Betaprime back into the aluminium container BETAPRIME VP 01706 A B A100B6070V Description Application Notes Adhesion promotor used to maximise the performance of the bonding between the cleaned and or activated surface and the adhesive compound Supplied in 250 ml aluminium containers of component A and component B Thoroughly shake component A container to disperse solid material Remove the lid from the component A container and scrape any sediment from the botton of the container Replace the container
15. he centre section on the bulkhead with Betaclean 3900 and Betaprime 5404 and apply Betaseal 1701 Press the insulator panel into position and ensure sufficient compression of adhesive Tape in place until the adhesive has cured Refit remaining components in reverse order to removal
16. hesive to the bracket and clamp in position until the adhesive has cured Rear Window Clean the whole of the bonding surface on the glass with Betawipe VP 04604 yellow cap and prime with Betaprime 5001 green cap Clean the corresponding surface on the bulkhead with Betaclean 3900 black cap and prime with Betaprime 5404 red cap Apply a bead of Betaseal 1701 to the periphery of the glass and press into position on the bulkhead to ensure sufficient compression of the adhesive Use a spatula to remove excess extruded adhesive and smooth any visual areas Tape the glass into place if necessary to retain position until the adhesive cures Bonding of Bulkhead Panel Clean the mating surfaces of bulkhead roll over bar and if fitted sill B posts with Betaclean 3900 black cap and prime with Betaprime 5404 red cap Or where applicable use Betawipe 4000 to re activate old adhesive refer to sub section BO 5 Clean the mating surface on the chassis with Betawipe VP 04604 yellow cap and prime with Betaprime 5404 red cap Apply a bead of Betaseal 1701 to the bonding path on the bulkhead and manoeuvre into postion pressing all round the joint path to ensure sufficient compression of the adhesive Use a spatula to remove excess extruded adhesive and smooth any visual areas Secure in position with tape until the adhesive has cured The heat acoustic insulator panel is bonded to the bulkhead only at its centre section Clean and prime t
17. ittings from the roll over bar backstays air cleaner roll over valve and remove both back stays 5 Taking suitable precautions remove the fuel filler hose and filler breather hose and cap the tank apertures to prevent dirt ingress and reduce fire risk 6 Release the evaporative emissions charcoal canister and fuel filter from their bulkhead mounting brack ets 7 Release the aerial lead from the bulkhead 8 Using a long knife cut the adhesive securing the insulator panel to the bulkhead and remove the panel to improve access to the bulkhead bonded joint 9 Using a sealant cutting knife cut the adhesive bead between the top section of the bulkhead and the roll over bar and between the bottom of the bulkhead and the chassis If the sill panels are fitted cut the bond between sill panel B posts and the bulkhead panel 10 Manoeuvre the bulkhead from the car To Fit Bulkhead Panel Before fitting a bulkhead panel ensure that the following parts are bonded to the panel Header tank mounting bracket Charcoal canister mounting bracket Immobiliser module stud plate Fuel filter mounting bracket Rear window glass All the above components are bonded using elastomeric adhesive applied as follows Refer also to sub section BQ 5 Brackets amp Studplates Clean the bonding surfaces on the bracket and bulkhead with Betaclean 3900 black cap and prime both surfaces with Betaprime 5404 red cap Apply Betaseal 1701 ad
18. licator nozzle Cut the nozzle end to the required diameter and shape Fit the cartridge into an air assisted gun and extrude a smooth even and continuous bead of Betaseal to the previously prepared substrate Assemble the joint within 5 MINUTES If the adhesive has to be touched or manipulated for any reason use only wetted fingers BETAMATE E2400 A082B8415V 220ml A100B6258V 450ml Description Two component chemically curing adhesive providing high strength permanently elastic bonds between various substrates Supplied in 220 and 450 ml aluminium cartridges Application An electrically driven Betagun Mk 11 is required to mix and extrude Betamate E2400 Refer to the operating instructions supplied with the gun Extrude a smooth even and continuous bead of Betamate to the previously prepared sub strate Assemble the joint within 5 MINUTES Notes If the adhesive has to be touched or manipulated for any reason use only wetted fingers Air gun Betaseal cartridge bj43 BQ 6 REPLACEMENT OF BONDED ON PANELS GENERAL Bonded body panels are secured using the Gurit Essex products Betaseal or Betamate which are flex ible polyurethane adhesives which must be cut in order for a panel to be removed The recommended method of adhesive cutting is with the use of a pneumatic tool such as the Chicago Pneumatic CP838 PneuNife which uses a range of differently shaped cutting knives to which is imparte
19. lid and thoroughly shake again to disperse the solid content Pour the required amount of component A into a clean container and add the same volume of component B Replace lids immediately Thoroughly mix the two components for 45 seconds minimum Leave the mixed components to stand for 30 MINUTES Discard if unused after 8 hours Pour the pnmer into the applicator bottle and wet out the felt pan by inverting the bottle and gently squeezing the sides Wipe the pad over the cleaned substrate surface to apply a continuous THIN film of primer A thin almost transparent film is all that is required No attempt should be made to attain a completely opaque covering Allow to dry for a minimum of 4 HOURS before applying adhesive To achieve a continuous thin film of VP 01706 apply in a smooth continuous uni directional movement not short backward and forward movements The latter technique results in incon sistent film build Replace the felt pad if moisture absorption results in hardening Never return unused Betaprime back into the aluminium container BETASEAL 1701 A082B6281F Description Application Notes m Page 8 One component moisture curing adhesive providing high strength permanently elastic bonds between various substrates Supplied in 300 ml aluminium cartridge Remove the cartridge end ensuring there is no damage to the reinforcing sleeve Pierce the neck of the cartridge and screw on the app
20. lled with two pairs of holes in the bracket to suit Rover and Toyota powertrain cars For Toyota powertrain cars use the innermost holes in the bracket to pull the sill panel furthest inboard Before preparing the surfaces for bonding ensure that the necessary pipes and cables are fitted to the chassis side rails RH side heater feed pipe brake pipe alloy spigot for side impact foam LH side heater return pipe brake pipe clutch pipe servo vacuum hose main battery positive cable alloy spigot for side impact foam Check that the following components are fitted into the composite sill RH side 2 a c pipes if applicable oil cooler return hose if applicable side impact foam foam baffle LH side oil cooler feed hose if applicable side impact foam foam baffle Prepare the bonding surface of the new sill panel with Betaclean 3900 and Betaprime 5404 see subsection BQ 5 Prepare surface of the old adhesive bead on the chassis and body panels Using Betawipe 4000 see sub section BQ 5 Apply a bead of Betaseal mate adhesive see sub section BQ 5 to the bonding surface on the chassis and body and fit the sill panel into position first locating the sill bottom edge into its chassis slot and press all around the joint to ensure sufficient spread of adhesive If necessary use a spatula to smooth or remove any extruded adhesive and to neaten any visual areas If necessary add adhesive to the joint
21. lls sills front compartment lid windscreen frame and rear bulkhead some panels being bonded to the aluminium alloy chassis with an elastomeric adhesive Acomposite panel may return to its original shape after deflection but beyond a certain level of flexibility such treatment may result in the formation of surface cracks which may not be immediately apparent due to the masking effect of the paint film A steel panel similarly treated would become dented or deformed The cracking may be confined to the surface layer with no reduction in panel strength but if the damage is more severe the composite structure below the surface may be weakened Localised repairs can be made in either case Possible causes of surface cracking include Vehicle collision Sitting leaning heavily or pushing on the body or any composite panel Knocking doors against obstructions when opening Dropping objects onto a panel Allowing unrestrained items to roll about in a luggage compartment Fitting a front access panel or closing the engine cover onto projecting objects e g luggage or tools Applying excessive force to parts attached to composite panels e g mirrors locks aerial etc inc action byvandals Incorrect jacking The composite body panels of the Elise are manufactured by one of several processes dependent on the requirements of the panel concerned The front and rear clamshells sill panels windscreen frame door outer panel
22. mination from the substrate surface Supplied in 1 litre aluminium container with a BLACK coloured cap Wipe on wipe off type When substrate is very dirty first wipe off the surface with a clean fibre free cloth and dis card Dampen a fibre free cloth with Betaclean 3900 and immediately replace the black cap Thoroughly clean the substrate surface with Betaclean and discard the cloth Wipe off the substrate with a clean fibre free cloth and discard BETAWIPE 4000 A082B6355V Description Application Cleaning agent which acitvates the old adhesive layer to accept new adhesive Supplied in 250 ml aluminium containers with a BLUE cap The residual adhesive bead should be cut with a scalpal to leave an even thickness of ap proximately 1 to 2 mm Dampen a fibre free cloth with Betawipe 4000 and immediately replace the blue cap Thoroughly clean the substrate surface with Betawipe and discard the cloth Do not wipe off Allow 2 3 minutes flash off time before applying adhesive BETAPRIME 5001 A100B6009V Description Application Notes Adhesion promotor used to maximise the performance of the bonding between the cleaned and or activated surface and the adhesive compound Supplied in 250 ml aluminium container with GREEN coloured cap Two steel balls inside the container are provided to assist mixing of the contents when shaken Prior to decanting Betaprime 5001 shake the container for at least 60
23. n sill and chassis body panels Note In the front wheelarch area a short section of the sill flange underlaps the windscreen frame buttress flange Unless the windscreen is also to be removed it will be necessary to cut the sill around this flange in order to release the sill The bottom edge of the sill and the rear part of the top edge locate in grooves in the chassis side frame and may not readily be cut out with the sill intact Cut the sill as necessary to release the panel and then remove the remaining edges of the panel from the chassis using a suitable cutting knife Cut the sealant around the door hinge post aperture Cut the sealant between the panel and roll over bar Bonding path Slots in chassis Door hinge siderail post Cut flange top corner if necessary m Page 16 Sill panel bj47a 10 11 Remove excess sealant from all the bonding areas on the chassis and body panels It is not necessary to remove all traces of old adhesive but any remaining adhesive must be securely bonded and be cut with a scalpal blade to leave an even thickness of 1 2 mm If necessary cut the top front corner of the sill flange to allow mating of the panel around the windscreen butress flange Dry fit the sill and fettle as necessary to achieve a good fit Note that a new sill will require an alloy right angle bracket A120B0053F riveting to the rear end of the sill panel to form a bonding surface Holes are pre dri
24. nal tubes formed in the construction are designed to produce a particular crush characteristic in order to control the rate of deceleration of the vehicle occupants in a frontal collision Crush tubes Radiator aperture Crash structure Airflow to climate chamber via cut outs in tubes m Page 10 To remove the crash structure Remove the front clamshell see sub section BR 5 Remove the front undershield by releasing the three screws securing each lower side of the structure to the shield and the three screws securing the shield to the front lower edge of the chassis Drain the coolant and remove the radiator and pipework see section KH Remove the driving lamps if fitted from the crash structure along with the towing strut horn alarm siren and wiring harness Use a seal cutting knife to cut the bond between the structure and the front face of the chassis For access to some of the bonding areas it may be necessary to cut away some parts of the structure rendering the unit unsuitable for refitment Take care not to damage the surface of the chassis when cutting the adhe sive It is not necessary to remove all traces of old adhesive from the chassis but a uniform surface must be available for the new adhesive bead The remaining adhesive must be securely bonded and be cut with a scalpal blade to leave an even thickness of 1 2 mm Prepare the new structure for bonding Dry fit the new structure t
25. o the chassis and check that a good fit is achieved Fettle the structure or remove old adhesive as necessary until the fit is satisfactory Re activate the surface of the old adhesive on the chassis using Betawipe 4000 see sub section BQ 5 and clean and prime the bonding area on the new crash structure using Betaclean 3900 and Betaprime 5404 see sub section BQ 5 Bonding surface on chassis Composite crash structure b278a Application of adhesive bead Betaseal bead b279 Apply a bead of Betaseal mate adhesive see sub section BQ 5 to the bonding surface in the manner shown Fit the structure to the chassis and press into position to spread the adhesive Use several clamps around the joint flange to retain the structure until the adhesive has cured This will take approximately 4 hours dependent on atmospheric conditions with a longer period required in dry atmospheres Fit the undershield radiator see sub section KH 4 front clamshell see sub section BR 5 and remaining parts BQ 8 WINDSCREEN FRAME The windscreen frame is a single ICSRTM moulding with hollow foam filled sections and incorporates a forward extending buttress at each side to brace the frame against the front chassis A separate dash baffle panel is used to bridge the space between frame underside and chassis scuttle and provide for the routing of climate control pipework and air ducting and other services Windscreen frame
26. pse This structure also acts as a mounting and duct for the engine cooling radiator which is mounted horizontally on its top surface BQ 2 LOTUS COMPOSITE BODY FEATURES Composite structures have the ability to absorb high impact loads by progressive collapse with impact damage being localised In vehicle accidents this feature protects the occupants from injurious shock loads and greatly reduces the danger of entrapment by deformation of steel body panels This behaviour also facilitates repair by either replacing the damaged bonded or bolt on panels and or integrating a replacement section with the undamaged area using recognised approved methods which restore the panel to its original condition without residual strain or distortion The manufacturing process enables the thickness of composite mouldings to be varied in order to provide efficient structures of high strength and low weight Composites will not corrode so the strength of composite components is retained regardless of age unless physical damage is sustained On the Elise the body con struction features an assembly of mouldings to form a single piece for the whole of the nose and front wings and a similar assembly for the whole of the rear body aft of the doors These two clamshells are fixed using threaded fasteners to permit easy removal for access to chassis or powertrain components or to allow simple and economic accident repair Other composite mouldings include the door she
27. s Use a spatula to smooth any visual areas to a neat finish Do not disturb the frame until the adhesive has fully cured see sub section BQ 5 Fit the windscreen see sub section BR 14 dash panel and instrument pack BR 13 front clamshell BR 5 and other components as necessary m Page 14 m indscreen frame bonding sills not shown Bonding path BQ 9 SILL PANELS The sill panels incorporate the A and B posts and are bonded to the chassis windscreen frame and rear bulkhead panel The sill bottom flange and rear end of the will top flange are bonded into grooves in the chassis main side rails and it is necessary to cut the sills in the course of their removal It is not practical to attempt to remove a sill panel intact for later refitment If sill damage occurs which is not repairable in situ the sill panel should be renewed To Replace Sill Panel A short section of sill flange underlaps the windscreen frame buttress flange in the front wheelarch area and requires that some cutting and laminating of the new panel is required on assembly 1 Remove front and rear clamshells see sub sections BR 5 BR 6 dash panel BR 13 and door hinge bracket BR 8 2 Remove the door latch striker pin and washers noting the assembly sequence Remove the door sill trim panel from the chassis and the door ajar switch from the sill panel 3 Use a sealant cutting knife to cut the adhesive bead betwee
28. s hard top roof outer panel and front crash structure are produced by Injection Compression System Resin Transfer Moulding ICS RTM whereby a mix of polyester resin and glass fibres is injected into a heated chrome steel surfaced closed mould After filling the gap between the two halves of the mould is then reduced in order to com press the moulding and ensure complete material flow and consistent structural quality Panel thickness is a nominal 2 2 mm The absence of the gel coat used with other processes results in much greater resistance to surface damage and minimum surface preparation for before painting O AL Page 3 O The front access panels engine cover lid door hinge panels door and roof inners and rear window shroud are produced from Low Pressure Sheet Moulding Compound LPSMC whereby flat sheets of composite material are formed using heated chrome steel surfaced moulds to produce panels with a nominal thick ness of 2 5 mm A third process is used for the cabin rear bulkhead bootbox and radiator mounting panel where the panel surface is not primarily visible These panels are produced by a Polyurethane Structural Reaction Injec tion Moulding PU SRIM process Body panels unique to the Exige model including front and rear clamshells door hinge cover panels and tailgate panel are hand lay composite mouldings with a nominal thickness of 2 5 mm Whichever production process applies conventional composi
29. te repair techniques can be used to rectify structural or surface damage whenever repairs can be determined as being more economic than panel replace ment BQ 3 BODYCARE The acrylic enamel paint finish of the Elise is extremely resistant to all normal forms of atmospheric attack Following the simple maintenance procedure summarised below will help retain the gloss colour and protective properties of the paint throughout the life of the vehicle However car finishes are not immune to damage and amongst the more common causes of deterioration are Atmospheric contaminants dust soot ash and acidic or alkaline aerosol mist can chemically attack paint Abrasion blowing sand and dust or a dirty washing cloth Tree sap and insect fluids can form a water insoluble polymer that adheres to the paint Bird excrement highly acidic or alkaline they can chemically etch the paint Wash off immediately Leaves contain tannic acid which can stain light finishes Impact damage granite chippings thrown up from poor or recently dressed road surfaces can subject the body to severe localised impact and result in paint chips especially around the vulnerable frontal panels Do not follow other vehicles too closely in such circumstances Washing Lotus recommends that the car be hand washed using the following instructions Many contaminants are water soluble and can be removed before any harm occurs by thorough washing with plenty of
30. the roof is fully dry before stowing as prolonged stowage of a wet or damp roof will promote rotting of the fabric os Keeping the soft top clean by regular washing will enhance the life and maintain the appearance of the roof and facilitate subsequent cleaning The use of stronger cleansers should be left to professionals experi Page 4 eu MMN enced in handling this type of fabric as discoloration and degradation of the special protective inner layer may result The application of wax finishes dressings or preservatives will cause stains which are difficult to remove and therefore should be avoided Paintwork Polishing Eventually some loss of gloss and an accumulation of traffic film will occur At this stage after normal washing the application of a good quality liquid polish will restore the original lustre of the paint film Higher gloss of the paint finish and added protection against contamination can be obtained by the use of a wax polish however this can only be used successfully on a clean surface from which the previous application has been removed with white spirit or a liquid polish cleaner Ventilation Water lying on the paint surface for a lengthy period will eventually penetrate the paint film Although the effects will not be visible immediately a deterioration in the protective properties of the paint film will ultimately result It is not recommended to store a wet car in a poorly ventilated garage If good
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