Lotus Esprit Series - Headlamp Bowls and Surrounds; Superficial Defect Repairs; Pin Holes or Air Voids

BODY
Page B11
rovings and resin, and whilst still wet, lay over o thin layer of chopped - strand mat
and
apply more resin + hardener (1 oz weight). Allow to dry ond fully cure. Sand
down and fill any imperfections with filler (Port No. A036
B 6203\/), and allow to
dry. Finally, sand down with carborundum paper to prepare for painting.
HEADLAMP BOWLS AND SURROUNDS
Where severe damage to the headlamp bowl and surround has occurred it
is generally
found more economical to
fit a replacement bowl and section. It is essential for the
correct operation of the headlamp assembl
y
that the replacement section is correctly
positioned, the bowl being attached to the pivot bobbins of the new section and
tested for
c~earancb in the up - and - down position before being bonded to the car.
The bowl should be fixed in the most convenient position by taping in place before
laminating in the new section. Accessibility
is restricted in this area and it may be
found mare advantageous to work through the actual
lamp unit hale.
Alternatively where a less serious impact
has occurred and the lamp surround can be
satisfactorily repaired without resorting to a replacement section it
is recommended
that a small
jig be made to embrace both pivot mounting bolts, of the bowl width.
These
can be screwed into the body bobbins serving to correctly locate them whilst
providing sufficient access to bond them in and perform the desired repoir.
SUPERFICIAL DEFECT REPAIRS
I,
i
PIN HOLES OR AIR VOIDS
It is difficult to overcome air voids and pin holes when a hand la
y
- u
p
repoir is carried
out, but, as all body components are heated to
82'~ (180°~), the maximum service
temperature, before painting, these imperfections
will show up. Any air voids
located in this manner con be opened up from the
surfoce ond filled with o stopper or
filler.
The air voids
and pin holes can be opened up using one or both of the following
methods:
(a)
Enlar
g
in
g
the hole by gonging or 'picking - out'.
(b)
Drillin
g
or routing out, leaving a large hole with near parallel sides.
If after repairing pin holes the paint surface sinks over the repair, this may have been
caused by the filler shrinking.
ESPRIT
.