Lotus Elise S1 Service Notes page 36

To remove the structure:
Remove the front clamshell (see sub-section BN.4).
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 KF).
Remove the driving lamps (if fitted) from the crash structure, along with the towing strut, horn 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 adhesive.
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-acivate the surface of the old adhesive on the chassis using Betawipe 4000 (see sub-section BM.5),
and clean and prime the bonding area on the new crash structure using Betaclean 3900 and Betaprime
5404 (see sub-section BM.5).
Composite
crash structure
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