Lotus 2004 Eleven Service Notes page 54

Lotus Service Notes
BQ.9 - SILL PANELS
The sill panels incorporate the 'A' and 'B' posts, and are bonded to the chassis, windscreen frame and
rear bulkhead panel. The sill bottom flange, and rear end of the will top flange are bonded into grooves in the
chassis main side rails and it is necessary to cut the sills in the course of their removal: It is not practical to
attempt to remove a sill panel intact for later refitment. If sill damage occurs which is not repairable 'in situ',
the sill panel should be renewed.
To Replace Sill Panel
A short section of sill flange underlaps the windscreen frame buttress flange in the front wheelarch area
and requires that some cutting and laminating of the new panel is required on assembly.
1. Remove front and rear clamshells (see sub-sections BR.5, BR.6), dash panel (BR.13) and door hinge
bracket (BR.8).
2. Remove the door latch striker pin and washers, noting the assembly sequence. Remove the door sill trim
panel from the chassis and the door ajar switch from the sill panel.
3. Use a sealant cutting knife to cut the adhesive bead between sill and chassis/body panels.
Note:
- In the front wheelarch area, a short section of the sill flange underlaps the windscreen frame buttress
flange. Unless the windscreen is also to be removed, it will be necessary to cut the sill around this flange
in order to release the sill.
- The bottom edge of the sill, and the rear part of the top edge, locate in grooves in the chassis side frame,
and may not readily be cut out with the sill intact. Cut the sill as necessary to release the panel, and then
remove the remaining edges of the panel from the chassis using a suitable cutting knife.
- Cut the sealant around the door hinge post aperture.
- Cut the sealant between the panel and roll over bar.
Door hinge
post
Cut flange
top corner
if necessary
Page 16
Slots in chassis
siderail
Section BQ
Bonding path
Sill panel
bj47a