Editing Footwell Corrosion (section)

===Official Lotus fitting guide===

Parts Required (as necessary)<br />
Part Number & Qty:<br />
Secondary Floor Panel Set A117A0235S, 1<br />
Betaclean 3900 Degreaser A100B6008V, 1 litre<br />
Betaprime 1707 A+B A111B6374V, 2 x 160ml<br />
Betaprime 5404 Primer A082B6337V, 1 x 250 ml<br />
Felt Applicator, Betaprime A000Z9088F, 4<br />
Betamate 2800 Adhesive B111B6159V, 2 x 80ml<br />
Mixer Nozzle, Betaseal adhesive A000Z9114F, 2<br />
Silastic RTV732, secondary floor panel A036E6027V, 1 x 310ml<br />
Carpet Set, RHD, black A117V0733S, 1<br />
Carpet Set, LHD, black A117V0734S, 1<br />
Carpet Fixing Stud, lower A117U6009F, 4<br />
Carpet Fixing Stud, upper A117U6008F, 4<br />
Velcro Strip, hook, self adhesive A111V6020V, 0.5m<br />

Tool Required: Applicator Gun, floor adhesive A117T0010S*, 1<br />
(*This tool will be mandatorily issued to all dealers and need not be ordered)

'''1.''' Remove the footwell divider panel and (if fitted) carpet retainer studs. Release all loose oxide from the footwell floors using a stiff nylon brush. Clean all loose material and debris using a vacuum cleaner. If any perforations are found, drill or file the holes to ensure that all corroded material is removed from the perforation site. Remove any burrs or sharp edges.<br /><br />

'''2.''' Dry fit the secondary floor panels, noting that the driver's side panel needs to be flexed to clear the gearchange mechanism. Trim panel edges if necessary to allow satisfactory fit. Note that any cut edges should be cleaned and primed during steps (3) and (4).<br /><br />

'''3.''' Degrease the footwell floors and underside of the secondary panels using Betaclean 3900.<br /><br />

'''4.''' Mix the two parts of the Betaprime 1707, and paint the whole of the footwell top surfaces and underside of the two secondary floor panels, using the felt applicator. Allow 30 minutes drying time.<br /><br />

'''5.''' Using Betaprime 5404, paint over the Betaprime 1707 on the footwell top surfaces and underside of the two secondary floor panels. Allow 15 minutes drying time. Then, for best results, continue immediately with step 6.<br /><br />

'''6.''' Cut the adhesive mixer nozzle to provide a 5 - 6mm aperture, fit onto the Betaseal 2800 twin pack cartridge, and insert into the applicator gun. Extrude sufficient adhesive onto a paper towel to acheive a consistently coloured black bead.<br /><br />

'''7.''' Addressing a single footwell floor, apply adhesive directly to any floor perforations to fully seal each hole. Then carefully apply a bead of adhesive around the periphery of the footwell floor, leaving a gap of about 10mm to the edge. Apply a further bead of adhesive in a zig-zag pattern as shown in the drawing overleaf. Note that the adhesive has only an 8 minute 'open' time before the secondary floor panel must be fitted.<br /><br />

'''8.''' Place the secondary floor panel into the footwell and apply even pressure to spread the adhesive. Ensure the panel is level and correctly aligned before applying sand bag weighting at front and rear for a minimum period of one hour. Check the underside of the footwell to ensure that adhesive is extruded through any perforations and smooth the material across the hole. Wipe off any excess. Clean any excess adhesive from interior alloy surfaces using Betaclean 3900.<br /><br />

'''9.''' Fit a new mixer nozzle before repeating steps (5) to (8) for the second footwell.<br /><br />

'''10.''' After a minimum period of 1 hour, apply a fillet of Silastic RTV 732 (A036E6027V) around the edge of each secondary floor panel ensuring that the joint is completely sealed. Smooth the sealant with a spatula for a neat finish.<br /><br />

'''11.''' When the Silastic is cured (allow 1 hour), refit footwell divider panel and passenger footrest.<br /><br />

'''12.''' Position the carpet studs using the new carpet as a template, and stick to the floor using a suitable locally sourced proprietary adhesive (e.g. Sikaflex). Stick half the length of Velcro strip to the front of each footwell approx. 20mm from the front edge, or from the passenger footrest.<br /><br />

'''13.''' Fit a pair of new 'breathable' footwell carpets using two fixing studs for each carpet. If applicable, trim the passenger carpet to suit the type of footrest fitted. If the customer wishes to fit any additional floor covering on top of the new breathable carpet, ensure this is properly restrained using either the carpet studs, or some other secure device.<br /><br />

'''14.''' Ensure that the customer is made aware that the footwell carpets should be lifted periodically and the floor cleaned and wiped dry.