Lotus Elan

Fitting a S4 DHC Screen !!!!!!!!! HELLLPP!

PostPost by: types26/36 » Thu Nov 25, 2004 7:40 pm

--- In ***@***.***, Marc Fuller <[email protected]> wrote:
Has anybody found a source for the tool that the Lotus manual
shows for

installing the windshield? I'll be up against the task soon, also.

You can make the tool to install the plastic trim, it does'nt need
the roller on it as the trim can be fed into the rubber and pressed
into place as the tool is moved along opening the gap.
As regards fitting the screens I tried with the cord but that did'nt
work so I fitted the rubber to the body, I then layed the screen in
the rubber at the bottom and worked round the screen with an
asortment of tools to lift the rubber while pressing the screen in.
The last bit was the most difficult to get the screen into the
rubber and also keep the rubber on the frame.
I also used washing up liquid to lubricate it, you should also do it
in the sun as the glass has less chance of breaking if it is
hot and the plastic filler bends better with heat.This was on my FHC
but I have also done it a couple of times on
my roadster so I dont think there can be much difference.
Good luck,
Brian
64Elan/72Sprint/J.P.S.Europa
Brian
64 S2 Roadster
72 Sprint FHC
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PostPost by: tvacc » Thu Nov 25, 2004 7:45 pm

I made the tool with a handle from a old garden tool (weeder as I recall)
.and bent some piano wire into a "diamond" with one of the points of the
diamond extending out so I could put it into the handle. I then epoxied the
wire in to the handle to keep it steady.epoxy did not last over the
years..but it still works.



You basically have to spread the rubber apart as you feed in the bead...



Have used it for years.



Tony V



_____

From: Brian Goodison [mailto:***@***.***
Sent: Thursday, November 25, 2004 2:40 PM
To: ***@***.***
Subject: Re: [LotusElan.net] Fitting a S4 DHC Screen !!!!!!!!! HELLLPP!




--- In ***@***.***, Marc Fuller <[email protected]> wrote:
Has anybody found a source for the tool that the Lotus manual
shows for

installing the windshield? I'll be up against the task soon, also.

You can make the tool to install the plastic trim, it does'nt need
the roller on it as the trim can be fed into the rubber and pressed
into place as the tool is moved along opening the gap.
As regards fitting the screens I tried with the cord but that did'nt
work so I fitted the rubber to the body, I then layed the screen in
the rubber at the bottom and worked round the screen with an
asortment of tools to lift the rubber while pressing the screen in.
The last bit was the most difficult to get the screen into the
rubber and also keep the rubber on the frame.
I also used washing up liquid to lubricate it, you should also do it
in the sun as the glass has less chance of breaking if it is
hot and the plastic filler bends better with heat.This was on my FHC
but I have also done it a couple of times on
my roadster so I dont think there can be much difference.
Good luck,
Brian
64Elan/72Sprint/J.P.S.Europa








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71 Spyder Elan, ElanGTS, 93 Caterham, 05 Elise,
99 Elise190, 91 M100 Elan, 74 Europa, 72 Europa JPS #15, 68 Elan Coupe RHD
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PostPost by: elans4dhc » Thu Nov 25, 2004 7:59 pm

The original query seems to suggest that a new screen frame has been added to the car in a conversion from fixed head to
drop head coupe. In my experience of new Lotus bodyshells, only two, I found that the screen aperture in both cases
was quite a bit undersize and the frame web had to be trimmed back on all four sides.

As to how much to trim back requires the screen to be held centrally in the screen aperture - I used lots of plasticine
(children's modelling clay) - and measure the gap remaining. It has to be big enough to accommodate the internal web
of the screen rubber. If it isn't, mark how much of the screen aperture needs to be removed all the way round to
achieve this, remove the screen, then file off the necessary glassfibre, refit the rubber and the screen goes in without
too much trouble. I've had to remove more than a quarter inch of the glassfibre web in some areas. What you must
ensure is that the windscreen and the glassfibre web of the screen aperture end up lying in the same plane - if the
windscreen plus the internal web of the rubber all the way round is greater than the size of the aperture then this is
not possible.

Hope this helps
Andrew
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PostPost by: "nebogipfel2004" » Thu Nov 25, 2004 8:52 pm

--- In ***@***.***, "Andrew King" <***@***.***e:
"The original query seems to suggest that a new screen frame has
been added to the car in a conversion from fixed head to
drop head coupe".

Hi Andrew,

Nearly correct ...... it is actually a DHC (Type45) which was
converted to FHC and I am returning it to DHC!!

When I put the screen within the aperture as you suggest I do have
plenty of clearance top and bottom but not so much at each side; I
suppose this may be the problem but the aperture measures much the
same as it was with the roof attached. I joined the pillars roughly
midway so the bottom and halfway up the sided should be pretty much
unchanged as is the rake angle.

I dunno but it is a bit of a bug**r

Thanks for all the advice ......I actually have the tool for fitting
the filler strip and would love to be at that stage. Even worse is
the fact that this is only a trial fit of the screen, it has to come
out again for the colour coats to go on!
"nebogipfel2004"
 

PostPost by: "Stan Aarhus" » Thu Nov 25, 2004 9:02 pm

In my experience of new Lotus bodyshells, only two, I found that the screen aperture in both >cases was quite a bit undersize and the frame web had to be trimmed back on all four sides.


Excellent point! I was drifting in that direction, but I think you have found it. I have removed and replaced the windscreen for my Coupe' twice, and had no trouble re-installing it either time. With that in mind, and since my screen is currently out, I had a chance to measure the flanges on my car. Measuring from the mid point of the radius to the edge of the lip gives 5/16 to 3/8 inch "lip width" all around.

Cheers!

Stan
"Stan Aarhus"
 

PostPost by: "nebogipfel2004" » Thu Nov 25, 2004 10:14 pm

--- In ***@***.***, "Stan Aarhus" <[email protected]> wrote:
>In my experience of new Lotus bodyshells, only two, I found that
the screen aperture in both >cases was quite a bit undersize and the

frame web had to be trimmed back on all four sides.


Excellent point! I was drifting in that direction, but I think
you have found it. I have removed and replaced the windscreen for

my Coupe' twice, and had no trouble re-installing it either time.
With that in mind, and since my screen is currently out, I had a
chance to measure the flanges on my car. Measuring from the mid
point of the radius to the edge of the lip gives 5/16 to 3/8
inch "lip width" all around.

Cheers!

Stan

If you get a chance Stan can you let me know the measurements edge
of lip to edge of lip of the vertical and horizontal size of the
screen aperture. My top to bottom is pretty much as it was before I
chopped the top (I wonder how it compares to yours?) but the width
of the hole is less certain because joining and strengthening the
pillars may have added a bit

Thanks in advance

John
"nebogipfel2004"
 

PostPost by: "Stan Aarhus" » Thu Nov 25, 2004 10:45 pm

John,

Ok, here are the INSIDE measurements of the windscreen opening.

Width
Bottom most width, at the crook of the sharp corner, straight across, in front of the dash = 46 1/2 inches
Midpoint width, at the drip edge screw hole, or if you don't have a drip edge, from 6 1/4 inches up from the crook = 43 1/2 inches.
Upper width, no result. unable to establish a reference point

Height
Driver's right, from behind the washer jet to the top edge = 19 1/4 inches
Mid point to the top edge = 19 3/4 inches
Driver's left, from behind the washer jet to the top edge = 19 1/4 inches.

HTH!

Stan



If you get a chance Stan can you let me know the measurements edge
of lip to edge of lip of the vertical and horizontal size of the
screen aperture. My top to bottom is pretty much as it was before I
chopped the top (I wonder how it compares to yours?) but the width
of the hole is less certain because joining and strengthening the
pillars may have added a bit

Thanks in advance

John
"Stan Aarhus"
 

PostPost by: jeff wolfson » Fri Nov 26, 2004 4:51 am

--- In ***@***.***, Marc Fuller <[email protected]> wrote:
Has anybody found a source for the tool that the Lotus manual
shows for

installing the windshield? I'll be up against the task soon, also.

Frost have it: see link below

http://www.frost.co.uk/item_Detail.asp?productID=8104

Jeff
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PostPost by: Arno Church » Fri Nov 26, 2004 6:11 am

Playing with soap in the shower helps!!!!!
Arno

Arno,
Do you lubricate the wives too?

Pete
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PostPost by: "Eric Salomon" » Fri Nov 26, 2004 7:41 am

Arno, I thought G & T and scotch worked better for you as a lubricant and softener with the women!

Eric

-----Original Message-----
From: Arno Church [mailto:***@***.***
Sent: 2004-11-26 08:14
To: ***@***.***
Subject: Re: [LotusElan.net] Fitting a S4 DHC Screen !!!!!!!!! HELLLPP!


Playing with soap in the shower helps!!!!!
Arno

Arno,
Do you lubricate the wives too?

Pete










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http://www.escribe.com/automotive/europ ... index.html
"Eric Salomon"
 

PostPost by: "nebogipfel2004" » Fri Nov 26, 2004 1:21 pm

Hi All

Stan, You are a star :) I'm sure the measurements will help.

As soon as I get another chance to work on the Elan I'll let you
know how I get on.


Thanks Again

John
"nebogipfel2004"
 

PostPost by: "nebogipfel2004" » Fri Nov 26, 2004 6:32 pm

Stan
I checked the measurements this and mine is within a gnats
thingy of yours so I reckon the hole is about right.

I had a bit of a go again this afternoon and can get three corners
of the b*gger in, it just will not roll back to allow the fourth
corner to drop in. I can't establish which bit is holding it.

I would bite the bullet and pay someone to do it but as I say this
is only a trial fit, I need to take it out again to paint the car

Cheers
John
"nebogipfel2004"
 

PostPost by: "Stan Aarhus" » Fri Nov 26, 2004 7:07 pm

John,

Here is another thought/guess. Are you using the original rubber gasket? If so, I'm stumped. If not and the gasket is a replacement, can you check that it's cross section is EXACTLY the same as the original? The critical dimension would be the thickness of the web between the two inverted "U"s. If this web is too thick it could be just enough to prevent the outer "U" from straddling the body opening lip while the inner "U" is enclosing the glass.

Again, FWIW

Stan
----- Original Message -----
From: nebogipfel2004
To: ***@***.***
Sent: Friday, November 26, 2004 12:31 PM
Subject: Re: [LotusElan.net] Fitting a S4 DHC Screen !!!!!!!!! HELLLPP!



Stan
I checked the measurements this and mine is within a gnats
thingy of yours so I reckon the hole is about right.

I had a bit of a go again this afternoon and can get three corners
of the b*gger in, it just will not roll back to allow the fourth
corner to drop in. I can't establish which bit is holding it.

I would bite the bullet and pay someone to do it but as I say this
is only a trial fit, I need to take it out again to paint the car

Cheers
John








To search the mailing list archives:
http://www.escribe.com/automotive/europ ... index.html
"Stan Aarhus"
 

PostPost by: "nebogipfel2004" » Fri Nov 26, 2004 7:30 pm

"Are you using the original rubber gasket?"

Stan, I appreciate the thought. I do not have the original, I
stupidly threw it away thinking I would not need it as it was rock
hard and really grotty. The rubber I am using is a replacement
supplied by Susan (Mick Miller) Lotus. It is quite a large section
rubber and is actually quite baggy on the screen (it falls off very
easily), but it looks like it should allow the screen plenty of
movement.

I take your point about the size of the internal part of the rubber
(between the two U sections) but it really looks as if the screen
should fall in!

Just thinking about it is bringing on a hot flush, I think I'd
better go and take my medication :))

Thanks Again
John
"nebogipfel2004"
 

PostPost by: type36lotus » Fri Nov 26, 2004 10:55 pm

John,

When I did my Coupe' It was a bear. I tried many times, for many
hours. My neighbor came over and offered to help, he felt that with
two of us it would go, after 2 - 3 more hours he too said let's give
up. I called a auto windhshield replacment company. Told them what
I had and how it mounted, made an appointment for a technician to
come out. Between the two of us the whole job, glass and trim was
about 20 minutes. What I was doing was right, just needed a second
person to know what to do also. The cost was $75 and worth every $.

Mike Geiger
66 S3 Coupe'

--- In ***@***.***, "nebogipfel2004"
<[email protected]> wrote:

Stan
I checked the measurements this and mine is within a gnats
thingy of yours so I reckon the hole is about right.

I had a bit of a go again this afternoon and can get three corners
of the b*gger in, it just will not roll back to allow the fourth
corner to drop in. I can't establish which bit is holding it.

I would bite the bullet and pay someone to do it but as I say this
is only a trial fit, I need to take it out again to paint the car

Cheers
John
Mike Geiger
66 S3 Coupe', no more :-(
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