Windscreen Frame; To Replace Windscreen Frame; Bu.4 - Lotus Evora Service Notes

Lotus Service Notes
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
Page 10
Section BU