Lotus Evora. Manual

Lotus Service Notes

Section BU

Front clamshell

indscreen frame*

Roof panel*

Rear

bulkhead*

entilatio

n panel

Tailgate

Reservoir access hatch

Rear

spoiler

Front bumper

'A' panel

Door

Body side panel*

Rear clamsh

ell

Rear bumper

* denotes panels bonded with elastomeric adhesive

b357

Evora Composite Body Panels

Lotus Service Notes

Section BU

BU.1 - GENERAL DESCRIPTION

The body panels of the Lotus Evora are constructed of composite materials, and contribute to the overall

stiffness of the body/chassis structure. The panels are attached to the aluminium chassis and/or other body

panels either by elastomeric polyurethane adhesive, where maximum structural integrity is required, or by

threaded fasteners, where ease of service access and repair is the greater priority. The windscreen frame

incorporates foam cores to create closed box sections for optimum strength and lightness.

BU.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 either by 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 pro vide

efficient structures of high strength and low weight. Composites will not corrode, so the strength of compos-

ite components is retained regardless of age, unless physical damage is sustained. On the Evora, the body

construction features a safety cell around the cabin, comprising an assembly of body panels bonded to the

chassis and to each other to provide maximum occupant protection combined with light weight. Both ahead of,

and behind the cabin, body panels are screw fixed to permit easy removal for access to chassis or powertrain

components, or to allow simple and economic accident repair.

A composite 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;

Inappropriately sitting, leaning heavily or pushing on the body or any composite panel;

Knocking doors against obstructions when opening;

Dropping or striking objects against a panel, including footballs and other wayward missiles;

Unrestrained items in the luggage compartment striking the inside of the rear body;

Attempting to close the tailgate onto projecting luggage or tools

Applying excessive force to parts attached to composite panels e.g. mirrors, handles and locks (inc. action

by vandals).

Incorrect jacking, or panel removal procedures.

The composite body panels of the Evora are manufactured by one of several processes dependent on

the requirements of the panel concerned:

All visible external panels, where surface quality is a priority, are produced by Injection Compression System

Resin Transfer Moulding (ICSRTM), whereby glass fibre mat cut to shape and preformed when necessary,

is placed in a heated, chrome steel surfaced, closed mould, into which polyester resin is injected. After

filling, the gap between the two halves of the mould is then reduced in order to compress the moulding

and ensure complete material flow and consistent structural quality. Panel thickness varies according to

strength/weight requirement. The special 'low profile' resin used ensures minimum shrinkage during the

curing process, in order to provide the optimum surface finish.

For less visible components, including the rear bulkhead, battery box, boot box and some reinforcement

panels, a Resin Transfer Moulding process is used with standard polyester resin injected at low pressure

into a double sided closed tool containing dry and preformed composite material.

For panels with a relatively simple shape and a low structural requirement, a Sheet Moulding Compound

(SMC) process is used, whereby a pad of material impregnated with resin is placed in a closed tool which

applies heat and a low compression to the moulding. A panel of high surface quality is produced, requiring

only a minimum of fettling operations.

Lotus Service Notes

Section BU

The front and rear bumpers are produced by a Reinforced Reaction Injection Moulding (RRIM) process,

whereby a mixture of polyurethane resin and milled glass is injected into a closed mould to result in panels

with good surface finish and high flexibility.

Whichever production process applies, if repairs can be determined as being more economic than panel

replacement, repair methods using either conventional composite techniques, or proprietary plastic component

repair systems, can be used to rectify surface or structural damage.

ICS components

Front clamshell outer

Rear clamshell outer

Bodysides

Tailgate inner

Roof

Door inners

Windscreen frame

RTM components

Rear bulkhead

Battery and boot boxes

Clamshell reinforcement panels

SMC components

Tailgate outer

Door outers

'A' post panels

Reservoir access hatch

RRIM components

Front and rear bumpers

BU.3 - BODYCARE

The acrylic enamel paint finish of the Evora 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.

Moisture entrapment; Long term use of a non-breathable car cover can trap moisture and/or induce con-

densation and promote water penetration of the paint film.

Washing

Lotus recommends hand washing of the painted bodywork. The car is a speciality sports vehicle not

intended to be subjected to an automatic car wash. Automatic car washing machines may have a detrimental

effect on the paint film and their use will invalidate the terms of the Vehicle Warranty.

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

Lotus Service Notes

Section BU

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 fa-

cilities ideal for this purpose, but to not use on the painted bodywork or vulnerable powertrain components or

delicate radiator finning.

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.

BU.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 & Reservoir Hatch;

- Front Bumper;

- 'A' Panels;

- Door Shells;

- Rear Clamshell;

- Rear Bumper;

- Tailgate;

- Ventilation Panel;

- Reservoir Hatch.

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 BV.

Bonded-on Panels: - Windscreen Frame;

- LH & RH Body Side Panels;

- Rear Bulkhead;

- Roof Panel.

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 shape, positioning and structure of the windscreen frame is crucial to the fit of the windscreen and

adjacent body panels, in addition to its behaviour in a vehicle collision. The only repairs which should be con-

sidered for this panel are cosmetic and superficial; any structural damage should be addressed by windscreen

frame replacement.

The body side panels include the ‘A’ posts, ‘B’ posts and cantrails, and involve much labour time to re-

place. Localised repairs should be performed whenever possible, if necessary using a partial section cut from

a replacement body side panel. Access to the inner surface should be considered when assessing cut lines.

Note that if damage is such as to require replacement of the chassis, a service replacement chassis is

Lotus Evora. Manual - part 4