Headlamp Bowls And Surrounds; Superficial Defect Repairs; Pin Holes Or Air Voids - Lotus Esprit Series Workshop Manual

rovings and resin, and whilst still wet, lay over o thin layer of chopped-strand mat
+
and apply more resin
down and f i l l any imperfections with f i l l e r (Port N o . A036
dry. Finally, sand down with carborundum paper to prepare for painting.
HEADLAMP BOWLS A N D SURROUNDS
Where severe damage to the headlamp bowl and surround has occurred i t i s generally
found more economical to
correct operation of the headlamp assembl
positioned, the bowl being attached to the pivot bobbins of the new section and
tested for c~earancb i n the up-and-down position before being bonded to the car.
The bowl should be fixed i n the most convenient position by taping i n place before
laminating i n the new section.
found mare advantageous to work through the actual lamp unit hale.
Alternatively where a less serious impact
satisfactorily repaired without resorting to a replacement section i t i s recommended
that a small j i g be made to embrace both pivot mounting bolts, of the bowl width.
be
can
These screwed into the body bobbins serving to correctly locate them whilst
providing sufficient access to bond them i n and perform the desired repoir.

SUPERFICIAL DEFECT REPAIRS

PIN O R
HOLES AIR VOIDS
I t is difficult to overcome air voids and pin holes when a hand la y -u p repoir i s carried
out, but, as a l l body components are heated to 8 2 ' ~ (180°~), the maximum service
temperature, before painting, these imperfections w i l l show up. Any air voids
located i n this manner con be opened up from the surfoce ond filled w i t h o stopper or
filler.
The air voids and pin holes can be opened up using one or both of the following
methods:
Enlar g in g the hole b y gonging or 'picking-out'.
(a)
Drillin g or routing out, leaving a large hole with near parallel sides.
(b)
I f
after repairing p i n holes the paint surface sinks over the repair, this may have been
caused by the f i l l e r shrinking.
hardener (1 oz weight).
fit
a replacement bowl and section.
that the replacement section i s correctly
y
Accessibility
has
Allow to dry ond fully cure.
B
I t i s essential for the
i s
restricted i n this area and i t may be
occurred and the lamp surround can be
Page
B11
Sand
ESPRIT
.