Lotus Elise S1 Service Notes page 39

Lotus Service Notes Section BM
9. If the dash baffle panel is damaged beyond 'in situ
1
repair, the panel must be removed by drilling out the
rivets and cutting the adhesive bead between the baffle and the chassis, and between the baffle and sill
panels. The clutch pipe, main battery lead and the heater distribution cable must also be released and
threaded through the panel.
10. To fit a new dash baffle:
- Dry fit the panel and check the fit at each end to the sill panels. Fettle as necessary.
- Prepare and re-activate the surface of the old adhesive on the chassis and sill panels using Betawipe
4000 (see sub-section BM.5).
- Clean and prime the bonding face on the new baffle panel using Betaclean 3900 and Betaprime 5404
(see sub-section BM.5).
- Apply a bead of Betaseal/mate adhesive (see sub-section BM.5) to the baffle flange.
- Position the panel and press along the length of the joint to ensure sufficient spread of adhesive. Retain
to the chassis with two rivets and clamp as necessary until the adhesive cures.
11. 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.
12. Fit the wiper motor assembly, windscreen washer jets and demist vents.
13. Ensure that the cant rails are available and assembled with their catch plates and new front end foam
seals. Check that the cant rail striker plates are fitted to the roll over bar.
14. - Prepare and re-activate the old adhesive bead on the chassis using Betawipe 4000 (see sub-section
- Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime
Primer band
If
^ T ^
BM.5).
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