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Lotus Evora. Manual - part 6

Lotus Service Notes

Section BU

5. Prepare the bonding surface of the new roof panel with Betaclean 3900 and Betaprime 5404 (see sub-

section BU.5). Prepare the surface of the residual adhesive on the body panels and seat belt frame using

Betawipe 4000 (see sub-section BU.5).

6. Apply a bead of Betaseal adhesive (see sub-section BU.5) to the bonding surface on the header rail, rear

bulkhead, body side panels and seat belt frame, and fit the roof into position. Press all around the whole

length of the joint to ensure sufficient spread of adhesive, if necessary using a spatula to smooth or remove

any extruded adhesive, and to neaten any visual areas. Where necessary, add adhesive to the jointline

to ensure complete weathersealing and neat appearance, and smooth with a spatula.

7. Clamp the panel into position until the adhesive has cured (see sub-section BU.5).

8. Refit displaced parts as necessary.

BU.8 - WINDSCREEN FRAME

The windscreen frame is an assembly of ICSRTM mouldings featuring hollow, foam filled sections, and

including a screen bottom landing panel, the two windscreen pillars and the windscreen header rail. The land-

ing panel is bonded to the chassis scuttle, the pillars to the body sides, and the roof panel bonds to the header

rail.

Localised damage to the frame should be repaired in situ using recognised techniques, but it is unlikely

that the complete frame will require replacement without the body sides and/or roof panel also being damaged.

Replacement of the windscreen frame will in any case require that the roof panel be removed, and the front

section of both body sides be released from the chassis.

The elastomeric adhesive bonding the frame to the scuttle and other body panels requires cutting with a

reciprocating knife, if necessary cutting the frame itself to allow improved access to the joint. It is unlikely to

be economic to attempt to remove a windscreen frame for re-fitment.

To replace windscreen frame

1. Remove the front clamshell (see sub-section BV.4) and wiper mechanism.

1. Remove the front clamshell, windscreen pillar trims, fascia top panel and headlining.

2. Remove the wiper mechanism and cut out the windscreen (see sub-section BV13).

3. Remove the roof panel (see sub-section BU.10).

4. Cut the adhesive securing both body sides to the chassis 'A' posts.

5. Remove the bracket securing the frame to the pedal box.

6. Cut the adhesive bond securing the frame to the chassis and to the body side panels, and remove the

frame from the car.

7. Prepare the old adhesive bead on the chassis and any existing body panels for fitment of the new wind-

screen frame by removing excess sealant from all the bonding areas 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. Any remaining adhesive must be securely bonded and be

cut with a scalpal blade to leave an even thickness of 1 - 2 mm.

8. If necessary, replace the foam sealing blocks between scuttle and frame using Betaseal products to clean,

prime and bond new blocks into position on the chassis.

9. - Prepare and re-activate the old adhesive bead on the chassis and other components using Betawipe

4000 (see BU.5).

- Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime

Lotus Service Notes

Section BU

5404 (see sub-section BU.5).

- Apply a bead of Betaseal 1701 adhesive (see sub-section BU.5) to the whole of the chassis bonding

flange on the windscreen frame, and to the body side panel flanges.

- Spring the body sides apart sufficiently to allow careful positioning of the windscreen frame onto the

chassis and locate with the tie bracket to the pedal box.

- Mate the body sides to the 'A' posts and windscreen frame.

- Press around all bonded joints to ensure adequate adhesive compression. Ensure the windscreen frame

is positioned correctly by measuring from the underside of each top rear end of the frame to the top sur-

face of the chassis siderail. Specification = 744mm. Compare diagonal dimensions to verify squareness.

Support the header rail in this position to prevent drooping until the adhesive cures.

- Ensure complete bonding between the frame and scuttle/foam blocks/other body panels, with no gaps,

if necessary extruding more adhesive into the joint.

- Use a spatula to smooth out or remove any excess adhesive, leaving a neat appearance, especially

where the joint will be visible.

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

11. Fit the windscreen (see sub-section BV.13), dash panel (BV.12), front clamshell (BV.4), and other compo-

nents as necessary.

BU.9 - BODY SIDE PANELS

Each body side panel incorporates the complete sill section, lower rear quarter panel ahead of the rear

wheelarch, ‘A’ and ‘B’ posts, door aperture and rear quarter window aperture. The panel is bonded to the chas-

sis, windscreen frame, rear bulkhead panel and roof.

The sill bottom flange is bonded into a groove in the chassis main side rail and it is necessary to cut the

panel to effect its removal: it is not practical to attempt to remove a body side panel intact for later refitment. If

damage occurs to the panel which is not repairable ‘in situ’, the body side panel should be renewed. However,

in view of the extensive amount of labour required to replace a body side, localised repairs or integrated sec-

tions should be considered wherever possible.

To replace body side panel

1. Remove front and rear clamshells (see sub-sections BV.4, BV.5), doors (BV.8) and roof panel (BU.10).

2. Remove electrical equipment fixed to the inside of the body side in the rear quarter area.

3. Remove the door weatherstrip seal and door latch striker plate.

4. Use a sealant cutting knife to cut the adhesive bead between body side and chassis, windscreen frame

and rear bulkhead. Also cut the adhesive around the door hinge faces, the striker plate face and the seat

belt mounting frame.

Note:

- The bottom edge of the sill locates in a groove in the chassis side frame, and may not readily be cut out

with the sill intact. Cut the sill as necessary to release the panel, and then remove the remaining edges

of the panel from the chassis using a suitable cutting knife.

5. Remove excess sealant from all the bonding areas on the chassis and body panels. 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.

6. Dry fit the body side panel and fettle if necessary to achieve a good fit.

7. Before preparing the surfaces for bonding, ensure that the necessary pipes and cables are fitted to the

chassis side rails and are in good condition:

Lotus Service Notes

Section BU

RH side: - Engine radiator return pipe

- A.C. feed and return pipes

- PAS feed and return pipes

- Right hand rear brake pipe

LH side: - Engine radiator feed pipe

- Heater feed and return pipes

- Clutch pipe

- Brake servo vacuum pipe

- Positive battery cable to front post.

Check also, by comparison with the displaced part, that the 'B' post reinforcement panel, and all neces-

sary bonded brackets and captive fixings, are correctly attached to the new sill panel.

8. Prepare the bonding surface of the new body side panel with Betaclean 3900 and Betaprime 5404 (see

sub section BU.5). Prepare surface of the old adhesive bead on the chassis and body panels Using Betaw-

ipe 4000 (see sub-section BU.5).

9. Apply a bead of Betaseal adhesive (see sub-section BU.5) to the bonding surface on the chassis, windscreen

frame and rear bulkhead, and fit the body side panel into position, first locating the sill bottom edge into

its chassis slot. Press all around the joint and ensure sufficient spread of adhesive, if necessary using a

spatula to smooth or remove any extruded adhesive, and to neaten any visual areas. Where necessary,

add adhesive to the jointline to ensure complete weathersealing and neat appearance, especially around

the door hinge post apertures, and smooth with a spatula.

10. Clamp the panel into position until the adhesive has cured (see sub-section BU.5).

11. Refit the dash panel, front and rear clamshells, doors, both wheelarch liners and other components as

necessary.

BU.10 - REAR BULKHEAD

The rear bulkhead is a Resin Transfer Moulded (RTM) panel and is bonded to the chassis and seat belt

mounting frame. The roof panel is bonded to its top flange, and the body side panels to each side flange.

A heat formed polyester fibre heat/acoustic insulator panel is bonded to the rear side of the panel. The

cabin rear window is bonded directly to the bulkhead using the same materials and procedure as is used for

the windscreen. A screw fixed panel is provided on the right hand side to allow access from the cabin to the

alternator, compressor and adjacent engine components.

Replacement of the complete bulkhead panel is unlikely to be required without a complete body rebuild.

In the case of localised damage, the panel should be repaired in situ using conventional hand lay techniques,

if necessary integrating a new section cut from a new bulkhead panel. The position of th e rear bulkhead is

critical to the fit of the tailgate and rear body section. If building up a new chassis tub, a jig assembled bulkhead

and rear seat belt mounting frame should be used, as a 3 - 5 mm standoff is required between the panel and

frame.

Rear Window: In order to minimise noise and heat transmission into the cabin, the rear bulkhead window is a

double glazed unit comprising two 4mm, toughened, clear, flat glass panes, separated by a 6mm void filled with

Argon gas. An obscuration band is applied to the rear face of both panes, with identification data read from

the engine bay side. The unit is bonded to the front face of the rear bulkhead panel using materials supplied

by Dow Chemical.

To replace the glass, remove the rear bulkhead trim and use a reciprocating knife to cut the bonding

medium. Clean the whole of the bonding surface on the new glass with Betawipe VP 04604 (yellow cap), and

prime with Betaprime 5500 (green cap). Clean the corresponding surface on the bulkhead with Betaclean 3900

(black cap) and prime with Betaprime 5404 (red cap). Apply a bead of Betaseal 1701 to the periphery of the

glass, and press into position on the bulkhead to ensure sufficient and uniform compression of the adhesive.

Use a spatula to remove excess extruded adhesive and smooth any visual areas. Support the glass in place

as necessary until the adhesive has cured suffiently.

Lotus Service Notes

Section BU

Bonding of rear bulkhead: The rear bulkhead panel is positioned by reference to the rear seat belt mounting

frame, and should be fitted only as a jig built assembly of bulkhead and frame.

Clean the mating surface on the bulkhead with Betaclean 3900 (black cap) and prime with Betaprime 5404

(red cap) or, where applicable, use Betawipe 4000 to re-activate old adhesive (refer to sub-section BU.5). Clean

the mating surface on the chassis with Betawipe VP 04604 (yellow cap), and prime with Betaprime 5404 (red

cap), or with Betawipe 4000 to re-activate old adhesive. Apply a bead of Betaseal 1701 to the bonding path on

the chassis, and fit the bulkhead/frame assembly into position by securing the frame with its four bolts to the

extruded brackets which form part of the chassis tub. If necessary, apply additional adhesive into the joint and

use a spatula to remove any excess extruded adhesive and to smooth any visual areas.

The rear bracing struts should then be shimmed as necessary to avoid corrupting this position. The stays

connecting to the front seat belt mounting frame should then be similarly shimmed.

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