Index Lotus Lotus Evora - service repair manual 2009 year

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Lotus Evora. Manual - part 5

Lotus Service Notes

Section BU

provided only as a 'partial body assembly' which includes jig bonded windscreen frame, body side panels, rear

bulkhead and roof. Also included, are the pipes, hoses and cables routed through the sills.

BU.5 - BODY PANEL BONDING MATERIALS

The materials used for bonding the body panels are manufactured by Dow Chemical, and in order to

main tain 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 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

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

Zinc plated and passivated steel

Cleaner: Betaclean 3900 Lotus part no. A100B6008V

Primer: Betaprime 1707 (A+B) Lotus part no. A111B6374V

Adhesive: Betaseal 1701 Lotus part no. A082B6281F

Glass

Cleaner: Betabrade F1 Lotus part no. A120B6043V

or Betaclean 3300 Lotus part no. A120B6042V

or Betaclean 3900 Lotus part no. A100B6008V

Primer: Betaprime 5500 Lotus part no. A120B6041V

Adhesive: Betaseal 1701 Lotus part no. A082B6281F

Uncoated Lexan/Perspex

Cleaner: Abrasion & dry wipe

Primer: Betaprime 5404 Lotus part no. A082B6337V

Adhesive: Betaseal 1701 Lotus part no. A082B6281F

Residual adhesive (i.e. rebonding to surface after cutting off old panel)

Cleaner, primer

& re-activator: Betawipe 4000 Lotus part no. A082B6355V

Adhesive: Betaseal 1701 Lotus part no. A082B6281 F

Applicator Bottle

An applicator bottle is available for use with some cleaners and primers, and has a 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

Lotus Service Notes

Section BU

container.

- 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.

Notes: - 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: Degreaser and cleaning agent used for the removal of contamination from the substrate surface.

Supplied in 1 litre aluminium container with a BLACK coloured cap.

Application: - 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.

BETABRADE F1 (A120B6043V)

Description: Liquid for removing contaminants from glass surface without scratching.

Application: Betabrade F1 may be applied to either (i) the glass surface, or (ii) a fibre free cloth.

i) Glass surface: Apply small beads of material, approx 3mm dia. x 50mm to the ceramic sur-

face of the glass. Use a fibre free cloth to thoroughly clean the ceramic surface of the glass to

be bonded and then wipe off all residual amounts. (A wipe on/wipe off process)

ii) Fibre free cloth: Apply material to the fibre free cloth and thoroughly clean the ceramic

surface of the glass to be bonded and then wipe off all residual amounts. (A wipe on/wipe off

process)

BETACLEAN 3300 (A120B6042V)

Description: Cleaner for glass and ceramic frit (coating).

Application: Betaclean 3300 may be applied to either (i) the glass surface, or (ii) a fibre free cloth.

i) Glass surface: Spray the material onto the ceramic frit (coating) of the glass around the

periphery and then using a fibre free cloth thoroughly clean the surface.

ii) Fibre free cloth: Apply the cleaner to the fibre free cloth and then thoroughly clean the ce-

ramic frit (coating). In both (i) and (ii) above the method is a wipe on/wipe off process.

BETAWIPE 4000 (A082B6355V)

Description: Cleaning agent which acitvates the old adhesive layer to accept new adhesive. Supplied in

15ml aluminium containers with a BLUE cap.

Application: - 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 5500 (A120B6041V)

Description: 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 con tainer

with GREEN coloured cap.

Application: - Two steel balls inside the container are provided to assist mixing of the contents when shaken.

Lotus Service Notes

Section BU

Prior to decanting Betaprime 5500, shake the container for at least 60 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.

Notes: - 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 5404 (A082B6337V)

Description: 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 con tainer

with RED coloured cap.

Application: - 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 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 24 hours, re-activate by applying a further coat of Betaprime 5404.

Notes: - 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 1707 A+B (A111B6374V)

Description: 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 con tainers

of component A and component B.

Application: - 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. Re place the

container 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.

Notes: - To achieve a continuous thin film of Betaprime 1707, apply in a smooth continuous uni-direc-

tional movement, not short backward and forward movements. The latter technique results in

inconsistent film build.

Lotus Service Notes

Section BU

- Replace the felt pad if moisture absorption results in hardening.

- Never return unused Betaprime back into the aluminium container.

BETASEAL 1701 (A082B6281F)

Description: One component moisture curing adhesive, providing high strength, permanently elastic bonds

between various substrates. Supplied in 300 ml aluminium cartridge.

Application: - Remove the cartridge end ensuring there is no damage to the reinforcing sleeve.

- Pierce the neck of the cartridge and screw on the applicator 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.

Notes: - If the adhesive has to be touched or manipulated for any reason, use only wetted fingers.

Plastic Panel Repair System

For repairs of cracked or damaged panels 'in-situ', plastic panel repair systems may be used such as Wurth

Replast, available under Lotus part number T000T1469F. Full instructions are supplied with the kit.

BU.6 - REPLACEMENT OF BONDED-ON PANELS - GENERAL

Bonded body panels are secured using Dow Chemicals products ‘Betaseal’ or ‘Betamate’, which are flexible

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 are widely available from specialist tool suppliers,

and which use a range of differently shaped cutting knives operating with a rapidly oscillating action. These

tools may also be used to remove windscreens.

An applicator gun for dispensing Betaseal 1701 adhesive may be obtained directly from PC Cox Ltd,

Turnpike Lane, Newbury, Berks. RG14 2LR Tel; +44 (0)1635 264500.

With some panels, it may not be practicable to attempt to removal intact for later refitment; damage to the

bonding flange is likely to occur. Consequently, when expedient, 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 achieved. Always use the specified materials.

Preferred practice is to paint the body panels prior to bonding into position (as factory build), firstly mask-

ing off all bonding surfaces on the panel.

BU.7 - ROOF PANEL

The composite roof panel is an ICS moulding which is last to be assembled, and generally the first panel

which needs to be removed. The panel is bonded to the top of the windscreen header rail, cabin rear bulkhead

panel, top flanges of the body side panels and seat belt mounting frame.

To replace roof panel

1. Remove the 'A' post covers and the roof lining if this is to be re-used.

2. Remove rear clamshell (see sub-section BV.5).

3. Using a pneumatic knife or cutting wire, cut the adhesive between the roof and header rail, body side

panels, rear bulkhead and seat belt frame, and remove the roof.

4. Remove excess sealant from all the bonding areas on the header rail, body side panels, rear bulkhead

and seat belt frame. 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.

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