Lotus Elise Service Notes page 41

Lotus Service Notes
Section TDM
16. Press over each part of the windscreen frame panel joint to ensure sufficient spread of the adhesive, and
use clamps as necessary to retain the frame whilst the adhesive cures. If necessary use a spatula to
smooth out or remove any excess or extruded adhesive.
17. Seal the frame panel to the top of the door hinge post at each side by extruding a bead of Betaseal, and
smoothing with a spatula to obtain a neat finish.
18. Examine the whole of the bonding jointline for sealing integrity, and if necessary apply additional adhe-
sive to seal any gaps. Use a spatula to smooth any visual areas to a neat finish.
19. Do not disturb the frame until the adhesive has fully cured (see sub-section BN.5).
20. Fit the windscreen (see sub-section BN.13), instrument binnacle and dash (BN.12), front clamshell (BN.4),
doors (BN.7) and other components as necessary.
BM.9 - SILL PANELS
The sill panels incorporate the 'A' and 'B' posts, and are bonded to the chassis, windscreen frame, dash
baffle, rear bulkhead panel and capping rail. The top and bottom flanges of the sill centre section are bonded
into grooves in the chassis sills, and it is necessary to cut the sills in the course of their removal: It is not
practical to attempt to remove a sill panel intact for later refitment. If sill damage occurs which is not repairable
'in situ', the sill panel should be renewed.
To Replace Sill Panel
A short section of sill flange underlaps the windscreen frame buttress flange in the front wheelarch area
and requires that some cutting and laminating of the new panel is required on assembly.
1. Remove front and rear clamshells (see sub-sections BN.4, BN.5) and dash panel (BN.12). Remove the
clamshell mounting bracket at the bottom corner of the windscreen.
2. Remove the cant rail striker from the top of the sill 'B' post to the roll over bar, and the door latch striker
pin.
3. Remove the speaker panel from the cabin rear corner, and remove the engine lid release cable from the
sill panel.
4. Use a sealant cutting knife to cut the adhesive bead between sill and chassis/body panels.
Note:
- In the front wheelarch area, a short section of the sill flange underlaps the windscreen frame buttress
flange. Unless the windscreen is also to be removed, it will be necessary to cut the sill around this flange
in order to release the sill.
- The rear bulkhead panel may need to be released from the chassis sufficiently to allow cutting of
the sealant between sill and bulkhead panel. Alternatively the sill can be cut as necessary to allow its
removal, and then the remaining sill flange removed with the improved access.
- The top and bottom edges of the sill centre section fit into grooves in the chassis side frames, 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.
- Cut the sealant around the door hinge post aperture, and the striker plate.
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. Cut the flange from the sill to match the windscreen frame buttress cut out made during removal. Dry fit
the sill and fettle as necessary to achieve a good fit.
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