Lotus Elan

Interior cardboard replacement.

PostPost by: elancoupe » Fri Jun 08, 2018 9:39 am

Looking to replace the carpeted rocker panels, and the quarter sail panels, which are made of the famous warped cardboard. I have experimented with thin plywood, and found it unsuitable. Interested to hear your experiences.
Mike
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PostPost by: pharriso » Fri Jun 08, 2018 10:23 am

Sue Miller makes & sells replacement panels in GRP (fibre glass), it's very thin, may .060"

You could make the same, lay up the fiberglass on a sheet of smooth varnished & polished plywood.
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PostPost by: elancoupe » Fri Jun 08, 2018 1:39 pm

I think that Sue?s part is pickup only, due to the size. :)


I could make them out of grp, but cutting them out of a sheet of something would be a lot easier.

I read something on here about using a type of thin plastic, haven?t been able to find it. #whatashock
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PostPost by: billwill » Fri Jun 08, 2018 1:58 pm

Old adverts, Estate agent signs etc are often printed on thin plastic sheets with two-layer-ribbed construction.
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PostPost by: oldelanman » Fri Jun 08, 2018 2:18 pm

I used 3mm foamed PVC sheet for the cockpit back panel and the rocker panels. It's lightweight, rot proof, cuts and bends easily and can be formed with a little heat from a hot air gun or hair drier.
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PostPost by: Chancer » Fri Jun 08, 2018 2:51 pm

Yup, - Foamex.

Try a local signwriting shop, offer to buy their offcuts, take plenty as you will be using it for years to come when you get to see its advantages.
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PostPost by: pcarew » Fri Jun 08, 2018 6:56 pm

I used the old panels as templates (had to tape the bits together :-) ) and then cut new ones out of 3mm hardboard.

A bit stiffer than I would have liked, but worked never the less.
dsc_0002_1.jpg and
New door panel

dsc_0003_1.jpg and
New Kick Panel riveted on
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1967 Lotus Elan S3SE Right Hand Drive, FHC 36/7152 BOO 758F
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PostPost by: webbslinger » Sat Jun 09, 2018 1:54 am

On the recommendation of a local upholstery shop I used automotive panel board. It worked great and it is supposed to be water proof and it is made specifically for auto restorations. The original pieces were fine but I didn't want to cut them to fit around the roll bar I added.
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PostPost by: elancoupe » Sun Jun 24, 2018 11:51 am

Just to follow up, I bought a sheet of 1/8" thick ash hardboard at the Home Despot, and it seems to be just right.

Thanks for all the input.
Mike
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PostPost by: lotusbzz » Mon Aug 20, 2018 8:14 pm

Hi !
I make sheeter for plastic and I got an order for inline sheeter of Bubbleguard that it?s like the polyethylene bubble pack but rigid because made of polypropylene and already laminated with a layer of non-woven that make easy and stronger the glueing of the carpet
I started with the inner sill then the job was so exciting that I cannot stop so I made back board, sills under dashboard panels trunk etc etc
Have a look of the pics
Ciao da bella Italia
Paolo
c72c7fb9-2634-4262-b3e4-357ea87c48cd.jpeg and

2376ef8e-7134-49dd-97a9-4a13b6dc2906.jpeg and

f9819e9d-84ed-47ad-bc51-203237c6cce2.jpeg and
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PostPost by: Elanman68 » Tue Aug 21, 2018 4:13 pm

Paolo,

Looks good, where did you get the Bubbleguard please, do you have a web link? I see you've used Dynamat as well, how is it?
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