Lotus 2004 ELISE Service Notes page 34

Lotus Service Notes
To remove the crash structure:
- Remove the front clamshell (see sub-section BR.5).
- Remove the front undershield by releasing the three screws securing each lower side of the structure to
the shield, and the three screws securing the shield to the front lower edge of the chassis.
- Drain the coolant and remove the radiator and pipework (see section KH).
- Remove the driving lamps (if fitted) from the crash structure, along with the towing strut, horn, alarm siren
and wiring harness.
- Use a seal cutting knife to cut the bond between the structure and the front face of the chassis. For access
to some of the bonding areas, it may be necessary to cut away some parts of the structure, rendering the
unit unsuitable for refitment. Take care not to damage the surface of the chassis when cutting the adhe-
sive.
It is not necessary to remove all traces of old adhesive from the chassis, but a uniform surface must be
available for the new adhesive bead. The remaining adhesive must be securely bonded and be cut with
a scalpal blade to leave an even thickness of 1 - 2 mm.
Prepare the new structure for bonding:
- Dry fit the new structure to the chassis, and check that a good fit is achieved. Fettle the structure or remove
old adhesive as necessary until the fit is satisfactory.
- Re-activate the surface of the old adhesive on the chassis using Betawipe 4000 (see sub-section BQ.5),
and clean and prime the bonding area on the new crash structure using Betaclean 3900 and Betaprime
5404 (see sub-section BQ.5).
Bonding surface on chassis
Composite crash
structure
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Section BQ
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