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Lotus Eleven/Elise/Exige. Manual - part 13

Page 12

Lotus Service Notes

Section BQ

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.

Application of

adhesive bead

Betaseal bead

b279

Windscreen frame

Dash baffle panel

Demist air duct

Face level

vent duct

Chassis scuttle

Heater pipe

b282b

Page 13

Lotus Service Notes

Section BQ

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 ob scured. 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 buttresses 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. If the 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

Dash baffle panel

Foam strip

b283b

Page 14

Lotus Service Notes

Section BQ

9. 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 A082U6065V to each vertical end face of the baffle panel, wrapping over

onto the top edge and along to the primed surface. Apply a second strip up each vertical face.

10. 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.

11. Fit the wiper motor assembly and windscreen washer jets to the windscreen frame.

12. 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 T000T1422F (RH) or T000T1423F (LH), which sould be

taped to the header rail for at least 30 minutes.

13. 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.

14. - 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.

15. 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.

16. Examine the whole of the bonding jointline for sealing integrity, and if necessary apply additional adhe sive

to seal any gaps. Use a spatula to smooth any visual areas to a neat finish.

17. Do not disturb the frame until the adhesive has fully cured (see sub-section BQ.5).

18. Fit the windscreen (see sub-section BR.14), dash panel and instrument pack (BR.13), front clamshell

(BR.5), and other components as necessary.

Page 15

Lotus Service Notes

Section BQ

Windscreen frame bonding (sills not shown)

Windscreen frame

Windsceen

frame

buttress

Dash

baffle

panel

Bonding path

b281a

Content .. 11 12 13 14 ..