Lotus Elise / Lotus Exige. Instruction - part 8

Page 6

 

 

Lotus Service Notes   

 

 

    Section BQ

BQ.5 - BODY PANEL BONDING MATERIALS

The materials used for bonding the body panels are manufactured by Dow Chemical, and in order to 

maintain the structural integrity of the vehicle, and in the case of the front crash structure, the safety, it is most 

important to use only the specified materials. The surface preparation and cleaning and priming operations are 

crucial to the performance of the adhesive, and must be followed in detail. The products to be used depend on 

the surface (substrate) onto which they are applied, and the following list identifies each application:

Anodised aluminium (e.g. chassis and components)

Cleaner:      Betawipe VP 04604      Lotus part no. A082B6150V

Primer:      Betapnme 5404         Lotus part no. A082B6337V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281F

        or  Betamate E2400        Lotus part no. A082B8415V

Unpainted or painted composite

Cleaner:      Betaclean 3900         Lotus part no. A100B6008V

Primer:      Betaprime 5404         Lotus part no. A082B6337V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281F

        or  Betamate E2400         Lotus part no. A082B8415V

Zinc plated and passivated steel

Cleaner:      Beatclean 3900         Lotus part no. A100B6008V

Primer:      Betaprime VP 01706 A+B  Lotus part no. A100B6070V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281F

Glass

Cleaner:      Betawipe VP 04604      Lotus part no. A082B6150V

Primer:      Betaprime 5001         Lotus part no. A100B6009V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281F

        or  Betamate E2400        Lotus part no. A082B8415V

Uncoated Lexan/Perspex

Cleaner:      Abrasion & dry wipe

Primer:      Betapnme 5404         Lotus part no. A082B6337V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281F

        or  Betamate E2400        Lotus part no. A082B8415V

 

Residual adhesive (i.e. rebonding to surface after cutting off old panel)

Cleaner, primer

& re-activator:  Betawipe 4000          Lotus part no. A082B6355V

Adhesive:    Betaseal 1701          Lotus part no. A082B6281 F

        or  Betamate E2400        Lotus part no. A082B8415V

Applicator Bottle

An applicator bottle is available for use with some cleaners and primers, and has a disposable felt pad 

which should be changed regularly to minimise surface contamination:

Applicator bottle:   A000Z1071F

Cap:          A082B6353S

Felt pad:        A082B6354S

Product Usage

BETAWIPE VP 04604 (A082B6150V):

Description:   Activator and cleaning agent used to promote adhesion to the substrate surface. Supplied in 

a 250ml aluminium container with a YELLOW coloured cap.

Application:    - Wipe on/wipe off type.

 

        - Pour Betawipe VP 04604 into applicator bottle, and immediately refit the yellow cap onto the 

container.

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Lotus Service Notes   

 

 

    Section BQ

 

        - Push the applicator head onto the bottle, and fit the felt pad.

 

        - Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.

 

        - Wipe the pad over the substrate surface using minimal pressure to wet the surface.

 

        - Immediately wipe off the activated/cleaned surface using a clean fibre free cloth, and dis-

card.

Notes:      - If the substrate is very dirty, first wipe off the surface with a clean fibre free cloth and dis-

card.

 

        - Do not leave the caps off Betawipe containers. A milky colour indicates moisture absorption, 

and the material should be discarded.

 

        - Only decant a sufficient quantity of Betawipe for the job concerned, and never pour material 

back into the container from the applicator bottle.

 

        - Change the felt pad at regular intervals to reduce surface contamination.

BETACLEAN 3900 (A100B6008V)

Description:   Degreaser and cleaning agent used for the removal of contamination from the substrate surface. 

Supplied in 1 litre aluminium container with a BLACK coloured cap.

Application:    - Wipe on/wipe off type.

 

        - When substrate is very dirty, first wipe off the surface with a clean fibre-free cloth and dis-

card.

 

        - Dampen a fibre-free cloth with Betaclean 3900, and immediately replace the black cap.

 

        - Thoroughly clean the substrate surface with Betaclean and discard the cloth.

 

        - Wipe off the substrate with a clean fibre-free cloth and discard.

BETAWIPE 4000 (A082B6355V)

Description:   Cleaning agent which acitvates the old adhesive layer to accept new adhesive. Supplied in 250 

ml aluminium containers with a BLUE cap.

Application:    - The residual adhesive bead should be cut with a scalpal to leave an even thickness of ap-

proximately 1 to 2 mm.

 

        - Dampen a fibre-free cloth with Betawipe 4000 and immediately replace the blue cap.

 

        - Thoroughly clean the substrate surface with Betawipe and discard the cloth. Do not wipe 

off.

 

        - Allow 2 - 3 minutes flash off time before applying adhesive.

BETAPRIME 5001 (A100B6009V)

Description:   Adhesion promotor used to maximise the performance of the bonding between the cleaned 

and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium container 

with GREEN coloured cap.

Application:    - Two steel balls inside the container are provided to assist mixing of the contents when shaken. 

Prior to decanting Betaprime 5001, shake the container for at least 60 seconds to disperse the 

solid content of the material into suspension.

 

        - Pour the primer into the applicator bottle and immediately replace the green cap.

 

        - Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.

 

        -  Wipe  the  pad  over  the  activated/cleaned  substrate  surface  to  apply  a  continuous  film  of 

primer.

 

        - Allow to dry for a minimum of 15 minutes before applying adhesive. If adhesive is not applied 

with 72 hours, wipe on/wipe off with Betawipe VP 04604.

Notes:      - The  appearance  of  the  primed  areas  should  be  deep  black  in  colour  with  no  streaks  or 

voids.

 

        To achieve this appearance, apply in smooth continuous uni-directional movement, not short 

backward and forward movements. The latter technique results in inconsistent film build.

 

        Rework any poor areas after 5 minutes (tack time), applying in the same direction.

 

        - Replace the felt pad if moisture absorption results in hardening.

 

        - Never return unused Betaprime back into the aluminium container.

 

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BETAPRIME 5404 (A082B6337V)

Description:   Adhesion promotor used to maximise the performance of the bonding between the cleaned 

and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium container 

with RED coloured cap.

Application:    - Two steel balls inside the container are provided to assist mixing of the contents when shaken.  

Prior to decanting Betaprime 5404, shake the container for at least 60 seconds to disperse the 

solid content of the material into suspension.

 

        - Pour the primer into the applicator bottle and immediately replace the green cap.

 

        - Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.

 

        -  Wipe  the  pad  over  the  activated/cleaned  substrate  surface  to  apply  a  continuous  film  of 

primer.

 

        - Allow to dry for a minimum of 15 minutes before applying adhesive. If adhesive is not applied 

with 24 hours, re-activate by applying a further coat of Betaprime 5404.

Notes:      - The  appearance  of  the  primed  areas  should  be  deep  black  in  colour  with  no  streaks  or 

voids.

 

        To achieve this appearance, apply in smooth continuous uni-directional movement, not short 

backward and forward movements. The latter technique results in inconsistent film build.

 

        Rework any poor areas after 5 minutes (tack time), applying in the same direction.

 

        - Replace the felt pad if moisture absorption results in hardening.

 

        - Never return unused Betaprime back into the aluminium container.

BETAPRIME VP 01706 A+B (A100B6070V)

Description:   Adhesion promotor used to maximise the performance of the bonding between the cleaned 

and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium containers 

of component A and component B.

Application:    - Thoroughly shake component A container to disperse solid material. Remove the lid from the 

component A container and scrape any sediment from the botton of the container. Replace the 

container lid and thoroughly shake again to disperse the solid content.

 

        - Pour the required amount of component A into a clean container, and add the same volume 

of component B. Replace lids immediately. Thoroughly mix the two components for 45 seconds 

minimum.

 

        - Leave the mixed components to stand for 30 MINUTES. (Discard if unused after 8 hours)

 

        - Pour the pnmer into the applicator bottle and wet out the felt pan by inverting the bottle and 

gently squeezing the sides.

 

        - Wipe the pad over the cleaned substrate surface to apply a continuous THIN film of primer:

 

        A thin, almost transparent film is all that is required. No attempt should be made to attain a 

completely opaque covering.

 

        - Allow to dry for a minimum of 4 HOURS, before applying adhesive.

Notes:      - To achieve a continuous thin film of VP 01706, apply in a smooth continuous uni-directional 

movement, not short backward and forward movements. The latter technique results in incon-

sistent film build.

 

        - Replace the felt pad if moisture absorption results in hardening.

 

        - Never return unused Betaprime back into the aluminium container.

BETASEAL 1701 (A082B6281F)

Description:   One component moisture curing adhesive, providing high strength, permanently elastic bonds 

between various substrates. Supplied in 300 ml aluminium cartridge.

Application:    - Remove the cartridge end ensuring there is no damage to the reinforcing sleeve.

 

        - Pierce the neck of the cartridge and screw on the applicator nozzle. Cut the nozzle end to the 

required diameter and shape.

 

        - Fit the cartridge into an air assisted gun, and extrude a smooth, even and continuous bead 

of Betaseal to the previously prepared substrate.

 

        - Assemble the joint within 5 MINUTES.

Notes:      - If the adhesive has to be touched or manipulated for any reason, use only wetted fingers.

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BETAMATE E2400 (A082B8415V - 220ml, A100B6258V - 450ml)

Description:   Two component chemically curing adhesive, providing high strength, permanently elastic bonds 

between various substrates. Supplied in 220 and 450 ml aluminium cartridges.

Application:    - An electrically driven Betagun Mk 11 is required to mix and extrude Betamate E2400. Refer 

to the operating instructions supplied with the gun.

 

        - Extrude a smooth, even and continuous bead of Betamate to the previously prepared sub-

strate.

 

        - Assemble the joint within 5 MINUTES.

Notes:      - If the adhesive has to be touched or manipulated for any reason, use only wetted fingers.

BQ.6 - REPLACEMENT OF BONDED-ON PANELS - GENERAL

Bonded body panels are secured using the Gurit-Essex products ‘Betaseal’ or ‘Betamate’, which are flex-

ible polyurethane adhesives which must be cut in order for a panel to be removed. The recommended method 

of adhesive cutting is with the use of a pneumatic tool such as the Chicago Pneumatic CP838 PneuNife which 

uses a range of differently shaped cutting knives to which is imparted a vibrating action. This tool may also be 

used to remove windscreens.

Supplier:                Chicago Pneumatic, Utica, New York 13501, USA.

Catalogue no.:            CP838 Pneu-Nife

Recommended air pressure:    60 - 90 PSIG (4.0 - 6.2 bar)

Tool air inlet:              1/4” NPTF, 3/8” mm. hose size

 

 

 

 

 

Air gun

                                                  Betaseal cartridge

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

          

 

bj43

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