B.1 - GENERAL DESCRIPTION - Section Menu The basis of the vehicle comprises a one piece moulded glass fibre reinforced plastic (G.F.R.P.) body shell which straddles a steel backbone chassis and is attached to it at the points illustrated.
Whilst the chassis carries all the major structural loads, the body is used to carry or transfer the remainder and when the body and chassis are correctly mounted, each contributes to the strength and torsional stiffness of the other.
Construction of the body is generally in laminated 2.4 oz. (68.54 grms) chopped strand mat. A high quality Polyester is used for the layup of all components giving a panel thickness of approx: .093 in. (2.30 mm). In the more highly stressed areas e.g. areas around side frames, metal inserts - especially major structural attachment points, seat mountings, floor areas and wheel arch lips - the thickness is increased up to .150 in. (3.80mm).
For replacement laminates or repairs any high quality commercial grade polyester can be used although it should be a type having a reasonably high heat distortion point (see Service Parts List).
The body shell is laminated basically as an upper and lower moulding with an additional front undertray chin piece which incorporates the extreme front chassis mounting points.
The nature of the design of all body panel joints is such that there are no critical or highly stressed bonds or joints in the body shell itself and the major problem in creating all wheelarch and bulkhead joints revolves around the need to obtain a perfectly waterproof or gasproof Joint as the case may be. B.2 - MANUFACTURING PROCESS - Section Menu General. The bonding or jointing of all panels and sections is in all cases provided by an adhesive or glueing action, and for this reason the efficiency of the bond is dependent on the following factors. Surface Preparation. When bonding to a moulded surface great care must be taken to remove all parting agents, e.g. wax or P.V.A. (Poly-vinyl-alcohol). Bonding Mix. Stressed Bonds. It therefore follows that these require more critical attention. Wet Bonded Joints. B.3 - ACCIDENT REPAIRS. - Section Menu Assessing Accident Damage As a general rule there should be a bond wherever two panels touch, or wherever they close on important points.
It is usually possible to check these bonds both visually and physically for fractures or breaks.
Ascertain the cause of damage and the direction of impact and examine all panels or bonds which may have been effected.
A front end impact for example may possibly cause the bonds at the bulkhead to split without the defect being normally visible and so on.
If necessary the metal on other components should be removed to facilitate examination as to the extent of damage sustained.
Before the assessment can be completed it is essential to decide on the repair method to be followed, the sizes of replacement panels to be ordered, etc. as the detailed instructions should be carefully followed.
The extent of the damage (and size of replacement panels) should take into account surface crazing.
Fire damage is the most difficult to assess but generally only the obviously burnt or charred sections will need to be replaced or reinforced.
The pedal mounting areas are heavily loaded and since failure of these in service could be fatal, they should be carefully examined if they have been close to the fire source. Basic Bonds and Joints Repair Materials. B.4 - SUPERFICIAL DEFECT REPAIRS - Section Menu Pin Holes or Air Voids A common problem of repaired pin holes is the sinking of the paint surface some time after the repair has been completed.
This may result from the use of a cellulose paint stopper which has a higher rate of shrinkage or in the case of a polyester stopper is usually caused by painting too soon after effecting the repair, before the filler is properly cured.
The filled areas should on no account be rubbed down until the filler has fully cured, or sinking will obviously result. Surface Crazing The crazing may not work its way through the paint surface for some weeks so that it is necessary when assessing accident damage to carefully examine all panels, particularly near cracks or split bonds and in cases of doubt it may be possible to promote the appearance of the crazing by applying gentle heat. Crazing itself generally stops at the first layer of glass fibre and is consequently not in itself structurally serious, but the extensive crazing near damaged areas should be taken as an indication of over stressing and the panel should be reinforced or replaced. It is not possible to remedy crazing by simply re-surfacing with a further layer of resin. Wrinkling or Distortion Split Bonds Replacement Sections Standard sectional repair moulds cater for the repair of damage in any area of the body unit. These are so designed that they can be used individually or connected together for the manufacture of the required section of the body. These are also used for locating new sections correctly relative to the existing panels. These moulds are deliberately left unframed so as to accommodate slight discrepancies and have been made on a standard painted body shell to allow for average paint thickness.
Repair sections available are shown in Figs. 6 and 7.
Due to the material used in construction of the body unit, cases of severe damage can often be economically repaired, i.e. where damage has been severe enough to destroy virtually the whole front end of the vehicle, as far as the bulkhead for instance, it is possible to graft on a new complete section.
Before cutting away the damaged parts or ordering replacement sections, the proposed method of repair, positioning of joint lines, overlaps etc. should be ascertained ('Section B.3').
Determine a method for the correct positioning of replacement sections and before cutting away damaged parts check on any prominent features from which measurements can be made and scribe these clearly on to the panels which are to be left intact.
Use masking tape or chalk to define the lines on which it is proposed to cut the panels and study these lines thoroughly to see that, (a) any damaged or slightly damaged panel which would be useful in the aligning of another major panel will not be removed or, (b) on single skinned areas in particular the proposed outline traverses longitudinal, lateral and horizontal definition points to assist easy lining up of the new panel in all three places.
When repairs have been carried out in the vicinity of the front wheelarches, ensure the tyres do not foul the front lower flange when the wheels are on full lock.
Underseal the wheelarch area to a depth of .125 in. (3mm) using '3M' material, or its equivalent in consistency, to prevent gel-coat crazing caused by small stones etc.; thrown up by the wheels. Positioning Replacement Panels Metal Inserts Bobbins They are designed to carry high loads in most directions and also offer the advantage of being accurately located in the mountings.
Two basic forms are employed as follows: Bobbins Pulling Out Difficulty may be experienced in temporary re-location of the bobbin and its surrounding laminate in its original position.
A local mould of the smooth side of the surrounding area (for example 6 in. (15 cm.) beyond in all directions) should eliminate this trouble.
Re-registering can be achieved by drilling holes through mould and body and through the bobbin before removing the repair mould.
Additional 4.00 in. (10.2 cm) square patches to make up to: ¼ in. and 5/16 in. bobbins: the equivalent of 5 x 1 ½ oz. layers. 3/8 in. and ½ in. bobbins: the equivalent of 7 x 1 ½ oz. layers.
The larger bobbins are used only where the loadings are known to be high, e.g. body mountings, seat attachments, etc. smaller bobbins are used as a locatory point or a blind attachment point.
Typical instances of non-structural applications are battery and spare wheel mounting points. In these cases loose bobbins can be repaired by more localized and less exacting means, e.g. forcing in a dough mixture around and behind the bobbin; winding tape around it, etc. Layup around Bobbins Stripped Threads When fitting, an initial check should be made with each bolt before tightening.
Only U.N.C. bobbins are employed and particular care should be paid to fit only U.N.C. bolts to them.
Where the bolts are particularly tight this may be due to resin within the threaded portion of the bobbin, which can be remedied by tapping out. Only the correct length of the bolt should be used, i.e. those whose thread engages with the full depth of the bobbin.
No attempt should be made to pull items up under heavy lead with a small engagement of thread.
To avoid tightening up onto the plain shank of the bolt it is recommended that only set screws be used, i.e. those threaded all the way up to the head. Laminating in a New Bobbin Finally plasticine or similar plugs should be used during laminating to keep the resin out of the bobbin threads.
When properly laid the visible rough side wall will be nearly vertical in line with the bobbin top profile.
In effect a strong reinforcing ring of laminate surrounds the bobbin and this ring must be properly connected to the basic laminate.
It is essential to keep the Gel-coat to a minimum thickness to prevent "crazing" and desirable that the general layup thickness tapers gradually away from the bobbins.
Remember that tensile applications are the most demanding and require continuity of layup, that the above instructions be strictly adhered to, that the safety of the vehicle may be dependent upon the correctness of the application of these operations. B.5 - BODY CARE - Section Menu When washing the body, use plenty of cold water; never attempt to remove dust or mud from the paintwork when dry, as this will damage the high gloss finish. Special preparations are marketed for adding to the washing water; the use of these mild "detergents", as directed by the manufacturers will expedite washing. Only use preparations of a reputable manufacture. When dust and mud have been removed with sponge and water, finally dry with a chamois leather.
If the car is kept clean by frequent washing, it will be found that polishing is almost unnecessary. If a polish is used, do not allow it to contaminate the windscreen.
During the months of winter, many countries use salt to assist in the clearance of ice or snow. Thoroughly wash the coachwork, the underside of the body and wings, and the chassis, either weekly or more frequently depending on local conditions, to remove any salt deposit and prevent its corrosive action.
The fibreglass coachwork will not of course be affected by any corrosive action but the metal parts attached could be.
Bright Metal Windscreen Cleaning Upholstery and roof lining Covers Ensure body is dry before using the cover. B.6 - PAINT PROCEDURE - Section Menu The following information applies to Polyurethane Primer Surfacer and is the full procedure when starting with a bare body.
Polyurethane Primer Surfacer was introduced into production as it gives more advantages through the complete paint process than was previously possible.
A full list of painting materials is given in Section 'B' of the Service Parts List.
To Paint NOTE:- If a fast thinner is used in cold or humid conditions, or lack of adequate air movement or heating exists in a spraying area, a commonly recognised defect known as "Blushing or Blooming" can occur on finish colour, (a milky dulling of the paint appearing soon after application, whilst the film is hardening).This is caused by the precipitation of atmospheric moisture due to the surface temperature of a newly applied paint film being lowered by solvent evaporation.
When this "Blushing or Blooming" is seen on the colour coats, it is also probable that any surfacers applied at that time and under those conditions will also be affected by this moisture precipitation. This is not usually visible since surfacers normally dry to a matt finish, but blistering of the paint system or faulty inter-coat adhesion may well occur later.
Painting Equipment. Paint Removal. The recommended procedure for removing paint is :- B.7- BONNET (HOOD) - Section Menu Bonnet To Replace: Tool Roll Strap B.8 - BOOT (TRUNK - ENGINE COVER). - Section Menu Boot lid To Replace: B.9 - DOOR TRIM PAD - Section Menu To Remove: To Replace: B.10 - DOOR LOCK REMOTE CONTROL - Section Menu Two types of lock remote control have been fitted in production, these being the lever type used on Series I vehicles and a second, flush-fitting type on Series II vehicles.
To Remove (Lever Type) To Remove (Flush type) To Replace (both types) B.11 - DOOR LOCK - Section Menu Two types of lock have been fitted in Production, these being dependent on the type of lock remote control used (Section 'B.10').
To Remove (first type) To Remove (second type) To Replace (both types) B.12 - LOCK STRIKER - Section Menu It is not necessary to disturb this component other than to fit a replacement or make adjustments.
To make adjustments, slacken the retaining screws in the striker, adjust as necessary and tighten the screws.
If the securing screws are inadvertently released, the screws tapping plate, which is BEHIND the door shut face will be displaced from its location.
To obtain access it will be necessary to remove the dust shield in the wheelarch (Section 'B.32'). B.13 - DOOR WINDOW MOTOR - Section Menu To Remove: To Replace: B.14 - DOOR WINDOWS - Section Menu To Remove: To Replace: B.15 - FITTING INSTRUCTIONS FOR REMOVABLE DOOR WINDOWS - Section Menu The following work can be carried out either with the doors still on the cart or removed on to a bench. The latter method is preferred, as this will permit more freedom of movement during the cutting and fitting operations. Always use a clean felt or foam-rubber covered workbench when working on body parts to avoid unnecessary damage to paintwork. B.16 - EXTERIOR DOOR HANDLE - Section Menu To Remove: To Replace: B.17 - DOORS. - Section Menu To adjust: Door Removal: To Replace: B.18 - SUN VISORS - Section Menu To Remove: To Replace: B.19 - FACIA PANEL - Section Menu To Remove: To Replace: B.20 - GLOVE BOX. - Section Menu To Remove: To Replace: B.21 - WINDSCREEN - Section Menu To Remove: To Replace: B.22 - REAR SCREEN (BACKLIGHT) - Section Menu To Remove: To Replace: B.23 - HEADLINING - Section Menu To Remove : To Replace: B.24- FRONT SEATS - Section Menu To Remove: To Replace: B.25 - BACKBONE TRIM - Section Menu To Remove: To Replace: B.26 - SAFETY BELTS. - Section Menu To remove: To Replace: B.27 - DUST SHIELDS (WHEELARCHES). - Section Menu To Remove: To Replace: B.28 - BUMPERS (FENDERS). - Section Menu Front. To Replace: Rear. B.29 - AIR INTAKE (RADIATOR) - Section Menu Grille. To Replace: B.30 - NAME BADGES - Section Menu All name badges with the exception of the nose badge, are retained by push-in clips.
If the necessity arises to remove the badges, new clips must be used when replacing,
The name plates are secured to their bezels by 'Araldite'.
The nose badge is retained by plain washers and nuts. Take care not to over tighten the nuts when replacing otherwise the enamel surface of the badge will become cracked. B.31 - BODY MOUNTING - Section Menu If reference is made to Fig.l, it will be seen what fixings are used at the various mounting points.
When fitting a replacement body, it is recommended that the body be 'offered up' to the chassis before fitting to ensure that mounting holes and bobbins 'line up' (see also 'Body Mounting Points' of Section 'B.4' and Section 'A').
Note that over-tightening of the mounting fixings can cause minor cracks in the body, this being the result of production tolerances on both body and chassis. Whilst this cracking is not serious, neither is it desirable, therefore insert a .375 in (9.5 mm) internal diameter plain washer between the body and its mounting to prevent this cracking. B.32 - WATERPROOFING - Section Menu The following information is published to assist in rectifying any water leaks, which may be apparent. This is of particular importance where new parts have been fitted.
The recommended sealers as approved by Lotus Cars Limited are: Doors: Seals Secondary Door Seals Access and Mounting Holes Drain Holes Windscreen, Rear Screen (Backlight), Fixed Glasses: Rubber Fitting Sealing Fixed Glasses Boot (Trunk): Seal Fitting Hinge Mounting Holes Wheelarches and Vent Boxes Seal all holes and mounting points, from the interior with Bostik '692' sealer.
Additionally, the wheelarches can also be sealed from the undersides with 3M body underseal, AFTER first removing ALL road filth. Fuel Tank Filler Neck General Fixed Windows {Series 1 cars) Removable Wlndows (Series 1 Mk.1 cars) ADDITIONAL INFORMATION - Section Menu
B.33 - BONNET (HOOD), FRONT - SubSection Menu Gel-Coat Crazing To overcome this, reaction pads should be attached to the underside of the lid at each rear corner. The pads (Part No. 046 B 1437) can be attached to the lid with Dunlop '758' adhesive. Bonnet Lifting B.34 - DOOR HINGE PIN - SubSection Menu When removing the door hinge pin, note that it is threaded 5/16 in. UNF at its lower end in order to facilitate removal. B.35 - BODY LEAN - SubSection Menu When a car has been re-bodied and re-built, the standing height should be measured at the wheelarches.
In cases where body lean is apparent (nearly always to the R/H side), washers (Part No. A054 B 1908) should be inserted between the body and the chassis at the mounting points. B.36 - INTERIOR MIRROR - SubSection Menu When and/or if an interior mirror becomes detached from its location, 'Loctlte 312' should be used, in accordance with the manufacturers instructions, to refix the mirror. B.37 - PAINT RECTIFICATION - SubSection Menu In addition to the information contained in Section 'B.6', the following gives advice in the recognition and rectification of certain paint defects which have been experienced on older cars. Rectification for the above defects is as follows:
Paint Blistering Primer Blistering Mat Blistering The full rectification for all listed defects is:- B.38 - DIRECT GLAZED WINDSCREEN {WINDSHIELD) - SubSection Menu Commencing at Chassis No. 7001010001R, all cars delivered where the U.S. Federal Motor Vehicle Safety Regulations are in force have been fitted with direct glazed windscreen (windshield).
In this method of windscreen retention, the glass is retained by a strip of butyl rubber compressed between it and the body aperture flange. A plastic trim strip is used to conceal the Joint. Existing windscreens are used, but all glazing rubbers and trim strips are deleted. The body aperture flange in which the windscreen is fitted, has been increased in depth to 9/16 in. (14.3am) in order to accommodate the new fixing method and this dimension MUST be maintained. Cars prior to the chassis number given above CANNOT be fitted with this method of windscreen retention.
All handling of the butyl rubber and plastic trim strip MUST be carried out at a MINIMUM temperature of 62°F. (17°C.) and a MAXIMUM temperature of 77°F. (25°C.), ideally at 65°F. (18°C.). This temperature restriction includes installation of the screen and compression of the butyl rubber. It may therefore be necessary to work in some area where the temperature can be raised (i.e. a spray booth, or similar). Before using any of the materials refer to the storage conditions and safety precautions at the end of this Section.
To Remove and Replace Windscreen PRESSURE MUST BE MAINTAINED UNTIL 40% COMPRESSION IS ACHIEVED.
This condition can be recognized by the .2 in. (5 mm) optimum width between screen and flange after compression.
STORAGE Plastic Trim Butyl Strip Primers If stored at temperatures BELOW 62°F. (17°C.), the materials must be conditioned within the working temperature range for 48 hours prior to use.
If there is any doubt about the conditions of any materials, or if the maximum storage life has been exceeded, the materials MUST be discarded.
The primers are TOXIC and highly inflammable, therefore every precaution MUST BE TAKEN to prevent fires and inhalation of vapours.
The following procedure MUST BE STRICTLY ADHERED TO: B.39 - PROTECTIVE WAX - SubSection Menu All cars are now protected with a protective wax, the wax used being 'Simonize' but not polished.
The wax can be removed by one of the following methods: NOTE: No attempt must be made to buff the existing protective wax, as this will only result in scratching the body, the wax being quite hard. B.40 - DOOR HINGE ASSEMBLY - SubSection Menu The importance of correct door adjustment is not always fully realized.
Incorrect door adjustment can cause the following troubles: Ensure that doors are correctly adjusted and if necessary, re-adjusted after initial body settlement. The doors should only be finally adjusted when the car is on its wheels on level ground.
To adjust the door, proceed as follows: Other Notes: [edit disabled for dial-up] |