Front Clam Removal - LotusTalk - The Lotus Cars Community

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post #1 of 24 (permalink) Old 09-18-2011, 02:03 PM Thread Starter
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Front Clam Removal

Cannot locate any existing threads on a complete write up on removing the front clam on a 05 elise. Anyone?

Thanks

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post #2 of 24 (permalink) Old 09-18-2011, 02:08 PM
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Lotus Elise Maintenance, How to Remove the Front Clam


If brute force doesn't work, you're not using enough.
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post #3 of 24 (permalink) Old 09-18-2011, 02:19 PM Thread Starter
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I love this site! Everyone is prompt and very helpful!

Thank You for the link!

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post #4 of 24 (permalink) Old 09-25-2011, 02:55 AM
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I had to replace my burst radiator.
Removing the front clam is not for the faint of heart. Take it slow and have a few extra people/eyes/hands. I am going to a specialist next time.

Here is another link: Remove S2 front clamshell - TechWiki

They also make some recommendations what to replace when it's off. I didn't make those, all looked very good. no point in fixing something that isn't broken.

->I suggest replacing the original radiator to an all aluminium radiator. The side plastic of the original are prone to rupture after 4 years of usage.
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post #5 of 24 (permalink) Old 09-25-2011, 07:29 AM
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Always glad to help!

Yes, with the clam off, there is a laundry list of stuff that you should do. Since you have an 05, do the resistor pack as well because it will fail. Brake lines, AC improvements (although you're in the north, may not be worth it), oil lines, etc. Good weekend fun!!

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post #6 of 24 (permalink) Old 09-27-2011, 02:28 PM Thread Starter
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If anyone wants their front clam off for any reason and lives near Pittsburgh I'll do it for half the dealer cost!! It only took me 2 hours!! I thought it was pretty easy...minus the bolts by the door hinge area. They are a bit tight. It was nice to see the car without the clam on and I vacuumed out any road debris that jumped in there that aren't visable with the clam on. The directions given were very helpful! Thank you again!

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post #7 of 24 (permalink) Old 09-27-2011, 02:44 PM
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Quote:
Originally Posted by KoenigElise05 View Post
If anyone wants their front clam off for any reason and lives near Pittsburgh I'll do it for half the dealer cost!! It only took me 2 hours!! I thought it was pretty easy...minus the bolts by the door hinge area. They are a bit tight. It was nice to see the car without the clam on and I vacuumed out any road debris that jumped in there that aren't visable with the clam on. The directions given were very helpful! Thank you again!
1) Does it also take 2 hours to put the clam back on?
2) If you removed it again would it take even less time?
3) What are the odds on breaking things during this whole process? I'd imagine that metal bolts would be OK. Were there any plastic clips that might break?

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post #8 of 24 (permalink) Old 09-27-2011, 04:33 PM
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Quote:
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1) Does it also take 2 hours to put the clam back on?
2) If you removed it again would it take even less time?
3) What are the odds on breaking things during this whole process? I'd imagine that metal bolts would be OK. Were there any plastic clips that might break?
1) Mine was less time to put back on.
2) I have removed mine three times now and yes, it takes me less time.
3) odds of breaking things are almost none, it does help to have some one help you when taking off and putting the clam back on to the car.
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post #9 of 24 (permalink) Old 02-22-2012, 08:08 PM
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As I just took mine off I figured I'd bump this thread. It was much much easier than I expected. I have a 2006 Exige and as I read the instructions I saw there are a few Elise things that are different (and much harder). Started Pulp Fiction just as I started removing it (already had wheels, etc off). Finished up around the time Butch kills Vincent with the silenced machine gun (less than 2 hours).
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post #10 of 24 (permalink) Old 02-22-2012, 08:42 PM
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Was reading your how-to, very nice and very helpful. Where is the factory throttle cable ran? I am swapping in a drive by cable throttle body into '06 elise chassis and not sure where to run it.
Thanks

Stuff sold by the gram is always more exciting than stuff sold by the pound. -JC
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post #11 of 24 (permalink) Old 02-22-2012, 08:52 PM
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Tagging this post. Good question one11


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post #12 of 24 (permalink) Old 03-18-2012, 08:48 AM
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I am in the process of removing my front clam, and am at the stage to take the headlights out. I have a 2007 Exige, so the underside of my headlight assembly does not match the pictures on Sands Museum or TechWiki sites. I do not have 5mm hex bolts. Based on the picture I have attached, it appears that the entire assembly has to be removed. Are the four nuts I have circled in the picture the ones that need to come out?
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post #13 of 24 (permalink) Old 03-18-2012, 09:41 AM
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Yah I am pretty sure you remove those bolts and lift up the headlight and get the one bolt under there. Go for it the time it takes is less then what it took you to post this


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post #14 of 24 (permalink) Old 03-19-2012, 10:14 PM
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Yup that did the trick. Thanks.
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post #15 of 24 (permalink) Old 06-02-2012, 08:53 PM
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first time was not the most fun but after that it is easy just takes a little time. Its amazing where some manufactures hide bolts and nuts lol
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post #16 of 24 (permalink) Old 08-29-2013, 05:11 AM
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Hi Guys

I have a 2008 exige trying to get the clam off for rad swap. Can only find guides for older models which majority is the same but there are some key differences.
Most of it is pretty loose both sides but there is still something that i cant see holding the middle down. Does the front grille come off and bolts behind? Or the grille above the rad doesn't look like it comes off either? Any ideas if you have done one?

Cheers
Mike

Last edited by mikeerhymes; 08-29-2013 at 05:18 AM. Reason: To subscribe to thread
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post #17 of 24 (permalink) Old 08-29-2013, 10:37 AM
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Originally Posted by mikeerhymes View Post
Hi Guys

I have a 2008 exige trying to get the clam off for rad swap. Can only find guides for older models which majority is the same but there are some key differences.
Most of it is pretty loose both sides but there is still something that i cant see holding the middle down. Does the front grille come off and bolts behind? Or the grille above the rad doesn't look like it comes off either? Any ideas if you have done one?

Cheers
Mike

Don't take the front grill out. There are the bolts under the headlights. There is also a mounting bracket right in the middle a few inches from the wiper arm. Where is it hung up? Did you get the lower two that bolt into the oil cooler brackets/radiator shroud?

It's pretty much the same as an Elise.
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post #18 of 24 (permalink) Old 08-30-2013, 01:53 AM
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thanks sprocket, yeah it was the two in the oil cooler brackets.

Getting the rad out was a pain in the arse too, i wouldnt look forward to having to do this again!
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post #19 of 24 (permalink) Old 07-11-2014, 07:38 PM
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Does anyone have an approximate number on how many shims go in each spot for the front clam. I pulled my clam off 6 months ago and am now absent minded and can't remember how much go where. I also have two shims that are shaped completely different and am thinking those go by the door, but can't find anything even on lotus garage about the shims.
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post #20 of 24 (permalink) Old 07-11-2014, 08:04 PM
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I'm pretty sure it is probably different on each car.
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