Creating UBERCLAM! Was "Repairing the clam" - LotusTalk

Randy Chase · 03-17-2006, 08:22 AM

It is time.

As some of you may know, I had a "situation" with my clam a while back. Bought the car in August 2004. In September, touched a curb/driveway thing and removed a chunk of the clam that was about the size of the palm of my hand. Hired a fiberglass repair specialist to come out to fix the clam and Starshield replaced the film so the car would be ready for SEMA, the first of November.

BUT.. driving back from Buttonwillow racetrack on I-5, I hit a large tire tread on the freeway... destroying my grill and cracking my clam, 2 days before SEMA.

I taped up the damage using clear packing tape and that worked quite well to hold things together. Decided I would deal with the damage later.

So over 15 months later... I am finding that the damage has spread as we expected it would and now, it has become quite bad. Pics to follow. The clam has fully split open along the license plate plinth so that it is hanging down. The only thing holding it together is tape.

I have been thinking of replacing the clam with an Exige clam, but ran into some trouble finding one for sale. I decided to go ahead with repairing the clam. Today.

Details to follow....

babak · 03-17-2006, 08:28 AM

After I cracked my clam at an autocross I printed Sandmans removal instructions and gave it to the body shop. It came quite handy. They were able to take the clam off without removing the wheels actually. One thing to look for is misalignment of the door as they open and close with the trailing edge of the clam after reinstallation. Easily fixed by slightly loosening the door bracket screws and readjusting the door.
Good luck.

milehitom · 03-17-2006, 08:44 AM

I had the same problem with my BRP nose job. Open the passenger door very slowly.-that seems to be the one the repair guy will forget to check after re-attaching the clam. I'll post pics of the finished product soon-just got it repainted and it's perfection! A clear bra will soon follow.

Tom

Stan · 03-17-2006, 08:51 AM

Quote:

Originally Posted by babak

After I cracked my clam at an autocross I printed Sandmans removal instructions and gave it to the body shop. It came quite handy. They were able to take the clam off without removing the wheels actually. One thing to look for is misalignment of the door as they open and close with the trailing edge of the clam after reinstallation. Easily fixed by slightly loosening the door bracket screws and readjusting the door.
Good luck.

If the door otherwise fits okay, leave it alone. You can adust the clearance and fit of the door's front edge, rocker, and clam. Just remove the service panels (triangular, covers the fuse box on one side) and you can access the needed fasteners. When the clam is adjusted side-to-side it moves the rocker with it.

babak · 03-17-2006, 09:00 AM

It was minimal if any rub. I just loosened the bracket screws and banged on it a couple of times. The alligment was off, there was a noticable step off from the trailing edge of the clam to the door.

Stan · 03-17-2006, 09:05 AM

Quote:

Originally Posted by babak

It was minimal if any rub. I just loosened the bracket screws and banged on it a couple of times. The alligment was off, there was a noticable step off from the trailing edge of the clam to the door.

I see. I think you can change the width of the clam about 1/4 inch per side if that will help. In maybe 10-20 minutes.

Andrikos · 03-17-2006, 09:30 AM

Quote:

Originally Posted by milehitom

I had the same problem with my BRP nose job. Open the passenger door very slowly.-that seems to be the one the repair guy will forget to check after re-attaching the clam. I'll post pics of the finished product soon-just got it repainted and it's perfection! A clear bra will soon follow.

Tom

Holy crap!
How much did that cost, if I may ask?

milehitom · 03-17-2006, 09:37 AM

$2k for the whole deal. My carbon-fiber fabricating friend did the repair for abotu $1200 and then I took it to a very nice collision shop for the paint job. I knew I was in the right place when I pulled in and they had another BRP getting painted, next to a Testarossa, a just finished '32 Cord and an old E Type in mid-restoration. Should have had my camera...

tom@kartboy · 03-17-2006, 09:41 AM

Randy
hit me up. i ahve roughly 15+ years composite experience. worked for Swift Engineering making the newman hass chassis. worked for Dupont Aerospace for many years.
were located off Miramar Rd. i can help or give you some pointers.

Tom

Andrikos · 03-17-2006, 09:43 AM

Wow! Is that all?
I was quoted $1,100+ for a small chip the area of an almond...
Grrrrr... Good thing I didn't follow through.

Randy Chase · 03-17-2006, 01:40 PM

Thanks Tom!

Here are some pics from today.

SilverArsenal · 03-17-2006, 01:41 PM

Wow, you really beat the crap out of that car. Better than driving off a cliff, I guess.

milehitom · 03-17-2006, 01:45 PM

For a second, I thought the second to last pic was you draped over the clam, sobbing...that's what I did. She'll be good as new soon!

Randy Chase · 03-17-2006, 01:51 PM

Quote:

Originally Posted by SilverArsenal

Wow, you really beat the crap out of that car. Better than driving off a cliff, I guess.

I will never win a concourse.

We are taking steps to make this area stronger. In my opinion, there are two vulnerable areas to be addressed. The square corner where the plinth joins the rest of the clam seems easily cracked, and the area where the chin jowls scrape on a steeper driveway.

We are going to reinforce these areas with Carbon-Kevlar.

Randy Chase · 03-17-2006, 01:53 PM

Clam off the car.

Interesting to see how they did the antenna. I am guessing it will be a maintenance item at some point to redo the clear tape.

Surferjer · 03-17-2006, 01:54 PM

RAndy, in my brand new car I nailed a frozen cone and already cracked the squared off spot. grrr. So I plan to fiberglass patch it one of these weekends soon. It's not nearly as bad as yours...yet.

TimMullen · 03-17-2006, 02:00 PM

Quote:

Originally Posted by milehitom

For a second, I thought the second to last pic was you draped over the clam, sobbing...that's what I did. She'll be good as new soon!

I thought the car was devouring Randy...

Randy Chase · 03-17-2006, 02:01 PM

But mine was not this bad either. This is from over a year of not doing anything about some smaller damage. It eventually vibrates to death.

P.S. Los Angeles just voted to go to 12" cones only instead of 18" cones. And yes, colder cones are bad. Ask Steve W.

Surferjer · 03-17-2006, 02:05 PM

Now that I pretty much know what to do and how simple it is, really, I'll fix it now and save some money later.

Steve W · 03-17-2006, 02:11 PM

Bah. Cold cones.

I think I'll try to get my car along to SCC and see what he says. The lesson from Randy's car is do something. I've patched the corners with fiberglass and bondo, so now when I scrape the clam I'm actually scraping the bondo. If I don't do anything else I'll do my own fiberglass patch to at least stop the damage from spreading.

03-17-2006, 08:22 AM	#1 (permalink)
Randy Chase Registered User Join Date: Apr 2002 Location: San Diego and where ever the roads lead Posts: 28,175 Images: 761	Creating UBERCLAM! Was "Repairing the clam" It is time. As some of you may know, I had a "situation" with my clam a while back. Bought the car in August 2004. In September, touched a curb/driveway thing and removed a chunk of the clam that was about the size of the palm of my hand. Hired a fiberglass repair specialist to come out to fix the clam and Starshield replaced the film so the car would be ready for SEMA, the first of November. BUT.. driving back from Buttonwillow racetrack on I-5, I hit a large tire tread on the freeway... destroying my grill and cracking my clam, 2 days before SEMA. I taped up the damage using clear packing tape and that worked quite well to hold things together. Decided I would deal with the damage later. So over 15 months later... I am finding that the damage has spread as we expected it would and now, it has become quite bad. Pics to follow. The clam has fully split open along the license plate plinth so that it is hanging down. The only thing holding it together is tape. I have been thinking of replacing the clam with an Exige clam, but ran into some trouble finding one for sale. I decided to go ahead with repairing the clam. Today. Details to follow.... __________________ * V E R I T A S * A E Q U I T A S * No Longer the ADMIN here, please do not PM me asking for help. Thanks! http://www.facebook.com/randychase 1991 Toyota MR2. AutoX Beast 2006 Noble M400. Track weapon. 2009 Rossion Q1. Monaco Orange. Canyon Carver. In build: 2009 Toniq R (300whp? 1100 pounds?). Chrome Orange. Lexus GX-470 tow vehicle. On Order: Lotus Evora Next: McLaren MP4-12C

03-17-2006, 08:28 AM	#2 (permalink)
babak Moderator Join Date: Oct 2003 Location: Topeka, KS Posts: 8,269 Images: 23	After I cracked my clam at an autocross I printed Sandmans removal instructions and gave it to the body shop. It came quite handy. They were able to take the clam off without removing the wheels actually. One thing to look for is misalignment of the door as they open and close with the trailing edge of the clam after reinstallation. Easily fixed by slightly loosening the door bracket screws and readjusting the door. Good luck. __________________ Babak Club111 Central Plains Coordinator '05 Elise - Touring, HT, StarShield '99 Ducati 996 Bip '05 Freelander SE

03-17-2006, 08:44 AM	#3 (permalink)
milehitom Registered User Join Date: Oct 2005 Location: Denver, CO Posts: 3,145	I had the same problem with my BRP nose job. Open the passenger door very slowly.-that seems to be the one the repair guy will forget to check after re-attaching the clam. I'll post pics of the finished product soon-just got it repainted and it's perfection! A clear bra will soon follow. Tom Attached Images

03-17-2006, 09:00 AM	#5 (permalink)
babak Moderator Join Date: Oct 2003 Location: Topeka, KS Posts: 8,269 Images: 23	It was minimal if any rub. I just loosened the bracket screws and banged on it a couple of times. The alligment was off, there was a noticable step off from the trailing edge of the clam to the door. __________________ Babak Club111 Central Plains Coordinator '05 Elise - Touring, HT, StarShield '99 Ducati 996 Bip '05 Freelander SE

03-17-2006, 09:41 AM	#9 (permalink)
tom@kartboy Registered User Join Date: Mar 2006 Location: San Diego,CA Posts: 95	Randy hit me up. i ahve roughly 15+ years composite experience. worked for Swift Engineering making the newman hass chassis. worked for Dupont Aerospace for many years. were located off Miramar Rd. i can help or give you some pointers. Tom __________________ Tom Deadrick www.kartboy.com tom@kartboy

03-17-2006, 09:37 AM	#8 (permalink)
milehitom Registered User Join Date: Oct 2005 Location: Denver, CO Posts: 3,145	$2k for the whole deal. My carbon-fiber fabricating friend did the repair for abotu $1200 and then I took it to a very nice collision shop for the paint job. I knew I was in the right place when I pulled in and they had another BRP getting painted, next to a Testarossa, a just finished '32 Cord and an old E Type in mid-restoration. Should have had my camera...

03-17-2006, 09:43 AM	#10 (permalink)
Andrikos Lulu ROX! Join Date: Jun 2005 Location: RanchoSahuarita.com , AZ Posts: 3,724	Wow! Is that all? I was quoted $1,100+ for a small chip the area of an almond... Grrrrr... Good thing I didn't follow through. __________________ My daily driver is an orange plastic toaster

03-17-2006, 01:40 PM	#11 (permalink)
Randy Chase Registered User Join Date: Apr 2002 Location: San Diego and where ever the roads lead Posts: 28,175 Images: 761	Thanks Tom! Here are some pics from today. __________________ * V E R I T A S * A E Q U I T A S * No Longer the ADMIN here, please do not PM me asking for help. Thanks! http://www.facebook.com/randychase 1991 Toyota MR2. AutoX Beast 2006 Noble M400. Track weapon. 2009 Rossion Q1. Monaco Orange. Canyon Carver. In build: 2009 Toniq R (300whp? 1100 pounds?). Chrome Orange. Lexus GX-470 tow vehicle. On Order: Lotus Evora Next: McLaren MP4-12C

03-17-2006, 01:41 PM	#12 (permalink)
SilverArsenal KLF HNGR Join Date: Feb 2005 Location: Studio City, CA Posts: 782	Wow, you really beat the crap out of that car. Better than driving off a cliff, I guess. __________________ Anyone who lives within their means suffers from a lack of imagination

03-17-2006, 01:45 PM	#13 (permalink)
milehitom Registered User Join Date: Oct 2005 Location: Denver, CO Posts: 3,145	For a second, I thought the second to last pic was you draped over the clam, sobbing...that's what I did. She'll be good as new soon!

03-17-2006, 01:53 PM	#15 (permalink)
Randy Chase Registered User Join Date: Apr 2002 Location: San Diego and where ever the roads lead Posts: 28,175 Images: 761	Clam off the car. Interesting to see how they did the antenna. I am guessing it will be a maintenance item at some point to redo the clear tape. __________________ * V E R I T A S * A E Q U I T A S * No Longer the ADMIN here, please do not PM me asking for help. Thanks! http://www.facebook.com/randychase 1991 Toyota MR2. AutoX Beast 2006 Noble M400. Track weapon. 2009 Rossion Q1. Monaco Orange. Canyon Carver. In build: 2009 Toniq R (300whp? 1100 pounds?). Chrome Orange. Lexus GX-470 tow vehicle. On Order: Lotus Evora Next: McLaren MP4-12C

03-17-2006, 01:54 PM	#16 (permalink)
Surferjer No more cone damage! Join Date: Dec 2003 Location: Exton, PA Posts: 8,885	RAndy, in my brand new car I nailed a frozen cone and already cracked the squared off spot. grrr. So I plan to fiberglass patch it one of these weekends soon. It's not nearly as bad as yours...yet. __________________ Jer-2005 Elise (retired from autox) 1993 MR2 autox car 2002 Ford Excursion DIESEL 4 X 4 1993 Miata (throwout bearing or clutch failure) 1987 Toyota Corolla FX16 Lemons car (needs new head) 1984 Chevy Citation Lemons car (needs a motor)

03-17-2006, 02:01 PM	#18 (permalink)
Randy Chase Registered User Join Date: Apr 2002 Location: San Diego and where ever the roads lead Posts: 28,175 Images: 761	But mine was not this bad either. This is from over a year of not doing anything about some smaller damage. It eventually vibrates to death. P.S. Los Angeles just voted to go to 12" cones only instead of 18" cones. And yes, colder cones are bad. Ask Steve W. __________________ * V E R I T A S * A E Q U I T A S * No Longer the ADMIN here, please do not PM me asking for help. Thanks! http://www.facebook.com/randychase 1991 Toyota MR2. AutoX Beast 2006 Noble M400. Track weapon. 2009 Rossion Q1. Monaco Orange. Canyon Carver. In build: 2009 Toniq R (300whp? 1100 pounds?). Chrome Orange. Lexus GX-470 tow vehicle. On Order: Lotus Evora Next: McLaren MP4-12C

03-17-2006, 02:05 PM	#19 (permalink)
Surferjer No more cone damage! Join Date: Dec 2003 Location: Exton, PA Posts: 8,885	Now that I pretty much know what to do and how simple it is, really, I'll fix it now and save some money later. __________________ Jer-2005 Elise (retired from autox) 1993 MR2 autox car 2002 Ford Excursion DIESEL 4 X 4 1993 Miata (throwout bearing or clutch failure) 1987 Toyota Corolla FX16 Lemons car (needs new head) 1984 Chevy Citation Lemons car (needs a motor)

03-17-2006, 02:11 PM	#20 (permalink)
Steve W \/ My Car! \/ Join Date: Oct 2003 Location: Los Angeles Posts: 1,147	Bah. Cold cones. I think I'll try to get my car along to SCC and see what he says. The lesson from Randy's car is do something. I've patched the corners with fiberglass and bondo, so now when I scrape the clam I'm actually scraping the bondo. If I don't do anything else I'll do my own fiberglass patch to at least stop the damage from spreading. __________________ B Team Driver driver.

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