Content .. 9 10 11 12 ..

Lotus Eleven/Elise/Exige. Manual - part 11

Page 4

Lotus Service Notes

Section BQ

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 composite 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 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.

4. Rinse the whole car to remove all soap from the fabric and to prevent streaking on the car bodywork.

5. Remove surface water with a sponge and allow to air dry in direct sunlight. Ensure that the roof is fully dry

before stowing, as prolonged stowage of a wet or damp roof will promote rotting of the fabric.

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 5

Lotus Service Notes

Section BQ

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 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 & 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 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.

Page 6

Lotus Service Notes

Section BQ

BQ.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