Lotus Elan and Lotus Elan Plus 2 Forums

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.

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.

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

Old adverts, Estate agent signs etc are often printed on thin plastic sheets with two-layer-ribbed construction.

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.

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.

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.

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.

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.

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

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?