Replacing the entire back of the fiberglass body

[Falco]

My car is severely damaged at the rear, so I have to cut of the entire back of the fiberglass body. I do have a non-damaged rear that i can use. The fibeglasswork is quite strait foreward, but cuting the glued parts free represent a problem to mee.

Please advise me in techniques and tools. (I have an other fiberglass body, where I can take the damaged pieces, but I have to remove the parts without damaging them. I intent to cut them apart where the are "glued" together)

Where can I get the "glue" needed for replacing an fixing the new parts ??

Any comments will be helpfull.

A lot of you in this forum must be experienced in fixing damaged fiberglass parts

[chrisP]

Hi there are references to replacing parts of the body work in the Elan Manuals, along with the cut lines, the required repair procedure and parts (glues) required. I'm sure someone can give you the exact chapter, as I don't have them to hand.
Chris

[L.G.]

Service manual section BJ is all about body repair. There is also a subtopic called "body removal" in BK. (body fittings)

L.G.

[Falco]

Service manual section BJ is all about body repair. There is also a subtopic called "body removal" in BK. (body fittings)

L.G.

Thanks both,

I will stúdy it a little bit closer
But my challange is to dismantle the different body-part in the joining - the "gluei stuf" - it is difficult to cut in this material

[surfboardfiller]

I'm not sure which sections you are removing but:

Cut the glass with an angle grinder using a thin cutting disk (not a grinding disk). Mask, goggles, gloves etc (I just had to write that). This takes the weight off the join and gives you easy access. You can then cut closer or on the join.

Dried sikaflex should be fairly hard in places but you may wish to try heating it if it's already soft and puling the trim off or cutting the glue with a Stanley type knife.

If you are not experienced at this, then I would advise that it isn't the best job to learn on (if it's the structural part of the tub). I don't know how capable you are, so forgive me if I seem condescending, I don't mean to.

Some parts would be best repaired using a jig.
May be you could post a few pics up and let us see what you are up against. The 'service notes' manual is excellent, I'd advise buying one before you start your project as it goes into great detail.

Good luck!

Cheers,

Phil

[Falco]

I'm not sure which sections you are removing but:

Cut the glass with an angle grinder using a thin cutting disk (not a grinding disk). Mask, goggles, gloves etc (I just had to write that). This takes the weight off the join and gives you easy access. You can then cut closer or on the join.

Dried sikaflex should be fairly hard in places but you may wish to try heating it if it's already soft and puling the trim off or cutting the glue with a Stanley type knife.

If you are not experienced at this, then I would advise that it isn't the best job to learn on (if it's the structural part of the tub). I don't know how capable you are, so forgive me if I seem condescending, I don't mean to.

Some parts would be best repaired using a jig.
May be you could post a few pics up and let us see what you are up against. The 'service notes' manual is excellent, I'd advise buying one before you start your project as it goes into great detail.

Good luck!

Cheers,

Phil

Now I have got the needed speacial tools for cutting the pieces apart

I have uploaded som pictures just to give an impresion of the repair

[lotusgirlmarie]

Now thats a job!!!

[Gary]

I reckon you need a thread in the projects area to keep us upto date with progress !

[Specky]

Are using the other shell for parts or using it to make a mould?

TTFN

[surfboardfiller]

I have uploaded som pictures just to give an impresion of the repair

Where did you put the pics?

[Doug]

there have been a few Elan owners in Denmark who have repaired or rebuilt Elans -- can't think of them off the top of my head, but maybe someone else can remember and get you their contact info . . .

[GeoffSmith]

there have been a few Elan owners in Denmark who have repaired or rebuilt Elans -- can't think of them off the top of my head, but maybe someone else can remember and get you their contact info . . .

He's already found Delta Doug!

[surfboardfiller]

Wow! that's exactly the car I am looking for! (I kid you not!) I have a brand new tub in storage (it's even Left Hand Drive) and I'm looking for a yellow car with rear end damage! LOL!
Maybe have a look on the lotus site to see if they have another one in their sale, it could save you a lot of time.



Top project though!
Jimbob's re build is worth a look if you haven't all ready.

[Falco]

Wow! that's exactly the car I am looking for! (I kid you not!) I have a brand new tub in storage (it's even Left Hand Drive) and I'm looking for a yellow car with rear end damage! LOL!
Maybe have a look on the lotus site to see if they have another one in their sale, it could save you a lot of time.



Top project though!
Jimbob's re build is worth a look if you haven't all ready.

After some thinking and evaluation, i thing the easiest way to do it is simply to cut whole chassis in half (the manual describes how to replace the middel of the car), so the result will be a LHD front with a RHD rear. This way I even can reinforce the joint if necessary (under the car or under the carpet)

[Paul.P]

After some thinking and evaluation, i thing the easiest way to do it is simply to cut whole chassis in half

Hope you mean body & not chassis ?

[surfboardfiller]

After some thinking and evaluation, i thing the easiest way to do it is simply to cut whole chassis in half (the manual describes how to replace the middel of the car), so the result will be a LHD front with a RHD rear. This way I even can reinforce the joint if necessary (under the car or under the carpet)

I thought that's what you would be doing (if you mean the bodyshell/tub); follow the seems. Make sure the fuel tank and all will match up before you do the switch.

[Falco]

After some thinking and evaluation, i thing the easiest way to do it is simply to cut whole chassis in half

Hope you mean body & not chassis ?

Oh yes, I mean the body and not the chassis

[Falco]

After some thinking and evaluation, i thing the easiest way to do it is simply to cut whole chassis in half (the manual describes how to replace the middel of the car), so the result will be a LHD front with a RHD rear. This way I even can reinforce the joint if necessary (under the car or under the carpet)

I thought that's what you would be doing (if you mean the bodyshell/tub); follow the seems. Make sure the fuel tank and all will match up before you do the switch.

Yes thank you I will make shure that it fits. but it looks like the is no major differences between the LHD and RHD rear

[F1 LOTUS]

[Dico]

I'm 99% sure they are the same, apart from the front bulkhead (pedal assembly, etc), and the aerial hole.