Lotus Eleven/Elise/Exige. Manual - part 23

         

        

Lotus Service Notes                                  Section BR

Page 32

BR.17 - WINDSCREEN 

(Parts List 11.01)

The laminated windscreen, together with self coloured synthetic finisher moulded around the top and side

edges, is bonded to the composite windscreen mounting frame using Betaseal flexible polyurethane adhesive.
It is not practicable to remove a windscreen from a car and then refit the same glass, as removal of the screen
will require cutting the surround finisher which is available only as part of a new windscreen assembly.

To Replace Windscreen
Parts required:

Windscreen
Betaseal Kit A075B6158F
Plinth, interior mirror mounting
Plinth Adhesive Kit A116U0194S

1.

On non-airbag cars, to minimise the possibility of trim damage, remove the fascia end (speaker) panels,
and the fascia top capping panel (around inside base of windscreen).

2.

Remove the front clamshell (see sub-section BR.6).

3.

Remove the wiper arm from its spindle, and the interior mirror from its plinth.

4.

Cut around the whole length of the windscreen surround finisher to allow access to the 'screen adhesive
joint.  Apply suction handles to the outside surface of the screen.

5.

In order to incur the minimum risk of damage to the windscreen composite mounting frame, the preferred
method of cutting the windscreen adhesive is by the use of a 'cheese' wire.  Protect the visual surface of
the windscreen frame with tape before commencing the cutting operation.

Screen removal tool

Cutting wire

        b322

         

        

Lotus Service Notes                                  Section BR

Page 33

6.

After cutting out the screen, remove old adhesive from the windscreen frame sufficiently to leave a
consistent and flat surface for the new bond.

7.

Clean the whole of the inside surface of the windscreen with a 50% solution of water and isopropanol.
Allow to dry.

8.

Fit the interior mirror plinth to the inside of the windscreen using the adhesive kit and instructions sup-
plied.

9.

Clean the whole of the inside surface of the obscuration band, and the bonding surface on the windscreen
frame with the wipe cleaner.

10.

Apply a 25 mm wide band of Betaprime around the inside periphery of the glass.  Similarly apply to the
whole of the bonding surface on the windscreen frame, and to the windscreen bottom laminated edge.
Allow to dry for a minimum of 5 minutes.  If the screen is not fitted within 48 hours, the primer should be
re-applied.

11.

Cut the nozzle of the Betaseal cartridge
to the dimensions shown to produce a
triangular section bead.  Holding the car-
tridge vertically, extrude a bead of ad-
hesive around the screen, using the edge
of the finisher as a guide along the top
and sides, and following the centreline
of the primer band along the lower sec-
tion.

Windscreen top edge

Screen centreline

Obscuration

     79mm

band

Mirror position on

63mm

  63mm

Mirror position on

RHD offset to left

LHD offset to right

        b263

   8 mm

10 mm

  60 mm

                b264

         

        

Lotus Service Notes                                  Section BR

Page 34

12.

Cut three 4mm spacer blocks from the material supplied in the Betaseal kit, or from rubber or plastic
material, and position in the inside edge of the adhesive bead running along the bottom of the class.
These spacers are used to control the fitted height of the glass, and the wiper arm clearance.

13.

Using the suction handles, carefully lower the windscreen onto the frame, with the edge finisher firmly
butted against the top and sides off the frame recess.  Press around the periphery of the screen to
compress the adhesive until contact with the finisher spacers and bottom edge spacer blocks is felt.
Carefully examine the integrity of the whole length of the joint, if necessary using a spatula to force extra
adhesive into any suspect areas.  Wipe off any excess adhesive extruded from the joint, or alternatively,
allow the adhesive fully to cure and cut away any excess using a scalpel blade.

14.

Use duct tape and/or support blocks to hold the screen in position and do not disturn until the Betaseal is
fully cured.  This will take approximately 4 hours dependent on atmospheric conditions, with a longer
period required in dry atmospheres.

15.

Refit wiper arm, interior mirror and front clamshell.

Cartridge nozzle

Betaseal bead

Edge finisher

Obscuration
band

Primer band

Bead along centre of primer band

Spacer block in inside edge of bead

      b265a

         

        

Lotus Service Notes                                  Section BR

Page 35

Spillage of material
a)

Any spillage of Betaseal onto unprimed glass can be readily peeled off after it has cured.

b)

Any spillage onto the bldy can be removed with either Wipe Cleaner No.4, or white spirit.

Shelf life
a)

Betaseal primer has a useful life of about 24 hrs. after exposure to the air, after which it starts to become
spongy.  If the material is spongy, DO NOT USE.  Always use glass primer immediately on opening, and
replace the lid after use.

b)

Betaseal has a shelf life of over 6 months at ambient temperature in the original unopened package.