Lotus 2004 ELISE Service Notes page 37

Lotus Service Notes
9. To fit a new dash baffle:
- Ensure the heater feed and return pipes are fitted.
- Dry fit the panel and mark up the bonding surface on the chassis scuttle.
- Prepare and re-activate the surface of the old adhesive on the chassis using Betawipe 4000 (see
BQ.5).
- Clean and prime the upper and lower bonding faces on the new baffle panel using Betaclean 3900 and
Betaprime 5404 (see sub-section BQ.5).
- Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the baffle lower flange.
- Position the panel and press along the length of the joint to ensure sufficient spread of adhesive. Clamp
the panel in position until the adhesive cures.
- Apply self adhesive foam strip A082U6065V to each vertical end face of the baffle panel, wrapping over
onto the top edge and along to the primed surface. Apply a second strip up each vertical face.
10. Prepare the old adhesive bead on the chassis for fitment of the windscreen frame by removing excess
sealant from all the bonding areas on the chassis, sill panels and dash baffle 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. The remaining adhesive must be securely
bonded and be cut with a scalpal blade to leave an even thickness of 1 - 2 mm.
11. Fit the wiper motor assembly and windscreen washer jets to the windscreen frame.
12. If necessary, fit a new roof side rail latch plate to the windscreen header rail - it is not recommended to
refit a bracket due to the requirement for high surface quality on the bracket.
- If applicable, completely remove any old adhesive from the header rail taking care not to damage the com-
posite substrate. Lightly abrade the bonding surface on the header rail but do not abrade the bracket.
- Clean the bonding surfaces on the header rail and bracket with Betaclean 3900 (see sub-section
BQ.5).
- Prime the header rail with Betaprime 5404, but do not prime the bracket.
- Generously coat the bonding surface of the bracket, with a 50/50 mix of Betamate 7064S (A116B0159V)
and Betamate 7014 (A116B0158V). Fit the bracket to the header rail and wipe off extruded adhesive with
Betaclean 3900. Position the bracket using tool T000T1422F (RH) or T000T1423F (LH), which sould be
taped to the header rail for at least 30 minutes.
13. Before fitting the windscreen frame, ensure that two setting rods are available for positioning the frame:
- Cut two 670mm lengths of locally sourced 10mm diameter steel rod.
14. - Prepare and re-activate the old adhesive bead on the chassis using Betawipe 4000 (see BQ.5).
- Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime
5404 (see sub-section BQ.5).
- Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the whole of the bonding flange on the
windscreen frame and butresses, including the mating face between frame underside and baffle panel.
- Carefully fit the windscreen frame onto the chassis and press into position to ensure adequate adhesive
compression. Ensure the frame is positioned correctly in relation to the roll-over bar by fitting the two set-
ting rods in the roof siderail locating slots. The rods should locate snugly in the slots with no end play.
- Clamp the frame into position until the adhesive cures.
- Ensure good adhesion between the frame and baffle panel.
- Use a spatula to smooth out or remove any excess or extruded adhesive.
15. 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.
16. Examine the whole of the bonding jointline for sealing integrity, and if necessary apply additional adhesive
to seal any gaps. Use a spatula to smooth any visual areas to a neat finish.
17. Do not disturb the frame until the adhesive has fully cured (see sub-section BQ.5).
18. Fit the windscreen (see sub-section BR.14), dash panel and instrument pack (BR.13), front clamshell
(BR.5), and other components as necessary.
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