Lotus 2004 Eleven Service Notes page 55

Lotus Service Notes
4. Remove excess sealant from all the bonding areas on the chassis and body panels. It is not necessary to
remove all traces of old adhesive, but any remaining adhesive must be securely bonded and be cut with
a scalpal blade to leave an even thickness of 1 - 2 mm.
5. If necessary, cut the top front corner of the sill flange to allow mating of the panel around the windscreen
butress flange. Dry fit the sill and fettle as necessary to achieve a good fit. Note that a new sill will require
an alloy right angle bracket (A120B0053F) riveting to the rear end of the sill panel to form a bonding surface.
Holes are pre-drilled, with two pairs of holes in the bracket to suit Rover and Toyota powertrain cars. For
Toyota powertrain cars, use the innermost holes in the bracket to pull the sill panel furthest inboard.
6. Before preparing the surfaces for bonding, ensure that the necessary pipes and cables are fitted to the
chassis side rails:
RH side: - heater feed pipe
- brake pipe
- alloy spigot for side impact foam
LH side: - heater return pipe
- brake pipe
- clutch pipe
- servo vacuum hose
- main battery positive cable
- alloy spigot for side impact foam
Check that the following components are fitted into the composite sill:
RH side: - 2 a.c. pipes (if applicable)
- oil cooler return hose (if applicable)
- side impact foam
- foam baffle
LH side: - oil cooler feed hose (if applicable)
- side impact foam
- foam baffle
7. Prepare the bonding surface of the new sill panel with Betaclean 3900 and Betaprime 5404 (see sub-
section BQ.5). Prepare surface of the old adhesive bead on the chassis and body panels Using Betawipe
4000 (see sub-section BQ.5).
8. Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the bonding surface on the chassis and
body and fit the sill panel into position, first locating the sill bottom edge into its chassis slot, and press all
around the joint to ensure sufficient spread of adhesive. If necessary, use a spatula to smooth or remove
any extruded adhesive, and to neaten any visual areas. If necessary, add adhesive to the joint around
the door hinge post, and to the windscreen frame, and smooth with a spatula.
9. Clamp the panel into position until the adhesive has cured (see sub-section BQ.5).
10. If the top front corner of the sill flange has been cut to fit around the windscreen butress flange, this area
should be reinforced as follows: Roughen the surface of the windscreen buttress flange and the adjacent
sill panel in the modified area, and lay up two pieces of chopped strand mat across the joint.
11. Refit the dash panel, front and rear clamshells, doors, both wheelarch liners and other components as
necessary.
BQ.10 - REAR BULKHEAD
The rear bulkhead is a Polyurethane Structural Reaction Injection Moulding (PU SRIM), incorporates the
rear window surround, and is bonded to the roll over bar and chassis fuel tank bay. A heat formed polyester
fibre heat/acoustic insulator panel is bonded to the rear side of the panel, and incorporates a glass fibre alu-
minised cloth heat reflector shield in the vicinity of the exhaust manifold. The rear window is bonded directly
to the bulkhead using the same materials and procedure as is used for the windscreen.
Section BQ
Page 17