Remove S2 front clamshell
NOTE: This article is very under construction
The front clamshell is a bonded assembly of several glass fibre composite mouldings incorporating both front wings, the front access aperture, radiator air intake and headlamp housings. The clamshell is secured to the windscreen frame, radiator mounting panel and other panels using threaded fasteners for ease of removal and to facilitate service access and body repair.
This article provides a step-by-step procedure to facilitate in the removal of the front clamshell to enable maintenance work to be carried out.
The time required is very dependant upon your competence with a spanner and how rusty the bolts are holding the clamshell on. However, SELOC members have commented on timescales of under half an hour!
The procedure is relatively simple given the fact your dismantling the front of your car. Only a few basic tools are required but a slow, methodical approach is highly recommended.
Procedure
- Raise car and support on front jack point with axle stands.
- Only need to loosen passenger side wheel arch liner.
- Disconnect the lights and switches. This is simple there is a bit on each plug/socket to squash with your fingers and they will then pull apart easily.
Mine has relay and fuse box mounted on it and the screws are a bugger to remove.
Drivers side wheel arch liner can easily be removed
The plastic screws sometimes will not come out so just carefully pry them out rather than unscrew (if they don't unscrew that is). You may need to replace some of these.
Also door hinge cover panels, you only need to remove the top two screws plus the hidden screw in the metal bracket attached to the windscreen mount. Sounds confusing but when you get stuck in it will make sense.
Just take your time and think about what you are doing and it will be fine.
Top Tips
- Never lift the clamshell from the car by yourself, you’ll crack it. Always get someone else to help and lift via the wheel arches
- The awkward bolts are those just behind the wheels that require the inner wheel arch to be pulled out to get access.
- Watch for the adjustment rivets between clamshell and mounting points (around the lid-aperture). Put them back where they were for alignment.
- When you get them back in at the end, don't push the rawlnuts through the holes, they will stay rolling around in the sill forever !
Whilst She's Off
There are a few other things that can be improved whilst the front clam is off, such as replace the radiator, replace the horn and replace the radiator fans.
External Links
http://www.sandsmuseum.com/cars/elise/experience/maintenance/frontclam/clamremoval.html