Door Glass Removal

[Gordon]

Is there a writeup anywhere on how to remove the door glass?
I've followed the instructions in the manual;

remove both upstop rubbers - OK
disconnect butterfly - OK
slide out window - err NO.

the back sliders wont clear out of the top of the rear glass channel.
I've loosened the track mounting nuts, but it's still not going to get through the gap between the inner and outer weather seals - am I missing something?

Gordon

[Doug]

I had to remove a few of the rivets on the inner metal liner to move it to allow the glass out. Otherwise what you wrote is the correct step up to there. The rivets were easy to replace after. Just drill out the back few if you can see what I mean ?

[Gordon]

Yes, looking at it, if I removed the inner seal assembly, the glass would out OK.
Didnt want to disturb all the silicone sealant if there was a quick cheat I couldnt see! (not mentioned in the workshop notes etiher - typical!!)
I'll get drilling rivits in the morning!
Thanks for the reply.

Does anyone know if there is a pattern replacement for the outer glass seal? - The one secured to the inside of the door skin with 10 rusty self-tappers?

[Darren]

Inner brush seal clamp needs to be removed i.e by drilling out the pop rivets like Doug said.

The outer seal is now available from Lotus but be warned that it's expensive. I'm also not sure if only the S2 inner and out seals are available which are a little shorter than the SE seals. I've fitted both & whilst the outseal is ok, the inner seal that holds the door card is a little short, mainly due to the fact that the S2 door seal is larger.

If you're going to remove the outer seal, then replace the screws with stainless alternatives, also be warned, the outer strip is reinforced with steel, so don't try to be clever and think it would be easier to cut the seal away.

With the door glass out, check over the motor assembly + lubricate the channels well & get someone to help you put the whole thing together as it's hard work to get the glass back in with a new outseal, as it tends to bend inwards and thus gets caught under the glass assembly when you're trying to push it down.

Darren.

[Gordon]

Genuine outer weatherstrips are certainly not cheap - current price seems to be £70 +Vat!
I'm looking at trying to use a pattern seal, which if it works, would be alot cheaper - I'll see how I get on... certainly needs to be secured with stainless screws - had a bit of a nightmare getting the rusty old ones out...

As I'm sure alot of people already know, the OBS glass support pads are no longer available... I'm thinking of making a batch from new parts (Aluminium strip, neoprene rubber block, and new brush strip) - if there's any demand for them that is...

Also, the aluminium tapping plate for the upstop bobbins - two of mine are scrap, and it seems they're £33+Vat each from Lotus - Why?! - need to find an alternative way of securing these to the glass...