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Discussion Starter #1
Before I get any further I will put my flame suit on, because there are a few people on here that do not like seeing something like this happening.

The subject in questions is the repair process of a Salvage Elise. I have been known to somewhat go off on some people that were selling their Salvage Elises. The reason being is because someone always tries to lie and deceive people. I am starting this thread as a purpose of keeping track of the repair and history of this car. This thread might also help some people with some of their repairs. If the thread will not help I might be able to ;)

I did not bump the very fist thread that I made about this car because I acted like an idiot. I will start over and use this as an educational project.

I am not trying to hide anything. This is an 06 Lotus Elise. It has 19XX original miles. Here is the vin sccpc11146hl30557 , Just in case someone googles it in any given situation. It does have a salvage title. So far I have about 95% of all the parts to finish it up. There is quite a few people on here that have tremendously helped me. I want to thank "keinayo" (Yoram) especially. He sent me his forced fed spoiler so I can shape the winglets. Yoram does not even know me, and he sent it to me based solely on trust. I just finished the winglets and returned the spoiler to Yoram.

Here are some pictures. Feel free to ask questions.

Spoiler


My materials. I purchased all of this at TAP Plastics. Very good quality and expensive. :up:

Foam




Resin


Fiberglass cloth




I need to find pictures of the clam when I was grinding off the cracked parts. But here how it was before I started.








I started with the winglets. I grinded off all the cracked parts. I used blue tape to form the winglets so that I can pour foam in them.





Foam right before it expands


Poured foam.




Then I used 100 grit sand paper to shape the winglets to a slightly smaller shape so I can lay a thicker layer of fiberglass.








Started laying the fiberglass. The trick is getting the material wet and squeeze as much resin out as possible. Resin is not what gives fiberglass strength.











Ok Im done for now. I will post more later. The winglets are now shaped. I just need to post some pictures.
 

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A....deja vu. :)
 

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Discussion Starter #3
Randy, the Uberclam thread was very helpful. A great thanks goes out to you as well
 

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Seems like even for the non-salvage people repairs like that will be needed frequently.
 

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Nice work. I have a 64 Elan that lived most of its life as a race car. It has been patched and repaired a large number of times. That is one of the beauties of fiberglass. The repairs will often be stronger than the shell being repaired. I even reinforced the floorpans in my Elan with a layer of CF in epoxy. For those who are unfamiliar with the Elan, the seat bolts directly to the body fiberglas and, if you are unfortunate enough to roll a few times, the seat can actually come out of the bottom of the car (ask Dave Bean).

The thing you want to beware of in fiberglass repair is the use of bondo rather than recreating structure with glass and resin. Bondo has no structural strength and should be used very sparingly.

Jerry
 

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Discussion Starter #10
Yes, I am not using bondo for strenght. I only use it to fix slight visual imperfections. I will reinforce a little from the inside as well.
 

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Discussion Starter #12
Not bad work at all. Is that your hobby or occupation?
Right now its a project. 1st time doing fiberglass. I will attempt to make a lip for this.. I dont know how that will turn out
 

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Looks good. Had something on a much smaller scale done recently to my car. you might think about putting a spoiler on when done to help protect it. Spoilers can get scratched on the bottom and not be a big issue versus having to do all that glass work again. And since you shaped it with a spoiler it should fit even better.
 

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Fascinating -- I want to try it!
 

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Discussion Starter #18
This is after it was sanded down







 

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Discussion Starter #19
Here is a little update.

I decided to fill the seam that the Elise has.. Partly because I would not be able to make the seam look the way its supposed since the crack was pretty close to the seam.

Here are a few shots of the area. Paint is stripped.
<center>
<img src="http://img.photobucket.com/albums/v113/akandok/elise/IMG_4186.jpg" alt="Photobucket - Video and Image Hosting"><br><br>
<img src="http://img.photobucket.com/albums/v113/akandok/elise/IMG_4187.jpg" alt="Photobucket - Video and Image Hosting"><br><br>
<img src="http://img.photobucket.com/albums/v113/akandok/elise/IMG_4188.jpg" alt="Photobucket - Video and Image Hosting"><br><br>
<img src="http://img.photobucket.com/albums/v113/akandok/elise/IMG_4189.jpg" alt="Photobucket - Video and Image Hosting"><br><br>
</center>

I already laid some fiberglass on it, just have to take some pics.
 
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