Lotus 2004 ELISE Service Notes page 56

Lotus Service Notes
Exterior lock/finger
grip bracket
4. Prepare the bonding surface of the door panel using coarse emery cloth and clean with Betaclean 3900
(A100B6008V). It is not necessary to remove all existing adhesive if this is securely bonded.
5. Apply a liberal quantity of ITW Plexus MA 920 adhesive (A117B0209V) to the door panel, and within a
maximum period of 4 Minutes (a longer open time will degrade adhesive performance) position the
bracket and ensure that the adhesive is extruded through the keying holes. Remove excess adhesive
which would interfere with any door functionality. Secure the bracket in position for a minimum of 30
minutes to allow adhesive to cure.
6. Re-assemble door and check for correct function.
7. If a latch mounting bracket needs to be rebonded, it is recommended to fit a cup washer A117W4192K
diagonally opposite (i.e. to the latch top mounting screw) to that already used on the inboard lower screw.
BR.9 - DOOR BEAM & HINGE
The door shell is bolted to a hollow section extruded aluminium alloy door beam, hinged at the front end
to the 'A' post, and carrying the door latch mechanism, via steel brackets, at its rear end. The front end of the
door beam is welded to a second extrusion which forms the rotor of the door hinge. The hinge stator (or hinge
bracket) is bolted to an outrigger on the chassis, and incorporates two cylindrical bearing housings fitted with
maintenance free pivot bushes.
Door hinge adjustments
In order to provide for adjustment of door shutlines, the door hinge may be adjusted in two ways:
i) Height of the hinge, its fore/aft position, and the pivot axis angle (to control the front/rear height align-
ment) may be adjusted after slackening the hinge bracket fixing bolts. The tapping plates for these bolts
are linked in vertical pairs and are captive, but loose, within the chassis outrigger, and allow for some
vertical movement. Horizontally slotted fixing holes in the hinge bracket allow for fore/aft movement.
ii) Slotted shim plates fitted between the hinge bracket and chassis, allow the in/out door front edge align-
ment to be adjusted in steps of 1 rnm, and by varying the shim pack at the top and bottom pairs of fixings,
the vertical alignment, as viewed from the front, may be adjusted.
Ensure that the clamping load of the hinge bracket to the chassis is not corrupted by the shim plates
bearing against the body. If the surrounding body stands proud of the chassis door hinge outrigger, use a
suitably cut down shim plate to act as a spacer between the chassis and the adjustment shim pack or hinge
bracket.
Window rear guide
channel bracket
6mm holes
Section BR
Shell to beam
front lower bracket
6mm holes
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