Lotus Esprit Series, Workshop Manual

Page: 39 / 362

Page
B11
rovings and resin, whilst s t i l l wet, l a y over o thin layer o f chopped-strand mat
and more resin
+
hardener (1 oz weight). Allow to dry ond f u l l y cure. Sand
down and f i l l any imperfections with f i l l e r (Port N o . A036
B
and to
dry. Finally, sand down w i t h carborundum paper to prepare for painting.
HEADLAMP BOWLS A N D SURROUNDS
Where severe damage to the headlamp bowl and surround has occurred i t i s generally
found more economical t o
fit
a replacement bowl and section. I t i s essential for the
correct operation o f the headlamp assembl
y
that the replacement section i s correctly
positioned, the bowl being attached to the pivot bobbins o f the new section and
tested for i n the up-and-down position before being bonded t o the car.
The bowl should be fixed i n the most convenient position by taping i n place before
laminating i n the new section. Accessibility
i s
restricted i n this area and i t may be
found mare advantageous t o work through the actual unit hale.
Alternatively where a less serious impact
has
occurred and the lamp surround can be
satisfactorily repaired without resorting t o a replacement section i t i s recommended
that a small be made to embrace both pivot mounting bolts, o f the bowl width.
These
can
be
screwed into the body bobbins serving t o correctly locate them whilst
providing sufficient access t o bond them i n and perform the desired repoir.
SUPERFICIAL DEFECT REPAIRS
PIN
HOLES
OR
AIR VOIDS
I t is d i f f i c u l t t o overcome a i r voids and p i n holes when a hand la
y
-u
p
repoir i s carried
out, but, as a l l body components are heated to the maximum service
temperature, before painting, these imperfections show up. Any a i r voids
located i n this manner con be opened up from the ond f i l l e d w i t h o stopper or
f i l l e r .
The air voids p i n holes can be opened up using one or both of the following
methods:
(a)
Enlarging the hole b y gonging or 'picking-out'.
(b)
D r i l l i n
g
or routing out, leaving a hole with near parallel sides.
I f
after repairing p i n holes the paint surface sinks over the repair, this may have been
caused by the f i l l e r shrinking.
ESPRIT
.