Body Side Panels; To Replace Body Side Panel; Bu.5 - Lotus Evora Service Notes

Lotus Service Notes
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:
Section BU
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