OP
OP
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- #21
📓 Journals Crash and Panel Blistering Repair
- Thread starter geoffbland
- Start date
This prefix is only usable in the Lotus Emira Journals forum.
Replace the yellow and green badge - sacrilege!!! 
Just throwing it out there that Fiat has a wonderful tricoat yellow they used. It might even be the same as the ferrari tri coat yellow.
How? You just need to wet sand the clear and spray the pearl and clear ontop. A color change requires wet sand, a base coat and clear. Same number of steps.
OP
OP
- Thread starter
- #24
It would be wet sand, base coat and (maybe) clear on the unpainted panels then pearl and clear on top of all panels. So 4 or 5 steps.
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Would be the perfect time to get some carbon vented fenders
vorsteiner.com
Lotus Emira Carbon Fiber LR-52 Vented Fenders
Vorsteiner Wheels Lotus Emira Carbon Fiber Vented Fenders – Enhance cooling and style with lightweight carbon fenders, designed for seamless integration on the Emira.
vorsteiner.com
OP
OP
- Thread starter
- #26
Nice idea but not really my style.
OP
OP
- Thread starter
- #27
Early June
The first week of June finally brought some excitement. Late on the Monday evening, I noticed via the tracker that my Emira had been moved out of storage and into Beaconsfield's workshop. Interesting...
The next day—conveniently lining up with my weekly "any news?" phone call (they must have been thoroughly sick of hearing from me by then)—I got some unexpected good news.
A large batch of parts had finally arrived. They'd already sent the van up to Silverstone a couple of times to collect them, and they could finally start putting my car back together. There were still a handful of parts missing, but those were expected the following week.
Beaconsfield also very kindly posted back the sunglasses I'd left in the Emira. Given the blazing UK summer we've been having, I'd actually been missing those more than expected.
With the rebuild underway, attention turned to finalizing the colour. We went backwards and forwards over several options, including Sun Glare Yellow, Inca Yellow (TR6), and TCX Blazing Yellow, the latter being my favourite at that point. The replacement paint had to be a solid (non-metallic) colour and also be compatible with the existing paint already on the car.
I resent some of the AI-generated images I'd created earlier using those colours to help make the final decision. I quickly discovered that AI is pretty useless for this sort of thing. It gives you a rough idea, but ask it to generate the same car in the same colour twice and you'll get two completely different shades. Great for inspiration, hopeless for choosing an actual paint colour.
However, the team at Beaconsfield looked at my favourite AI image and thought they could recreate the shade it was trying to emulate. Convinced they were onto something, they mixed up a batch of paint, grabbed one of the discarded Emira doors from their pile of blistered panels, and sprayed it as a test.
I hadn't asked them to do this—they simply had a hunch that the colour would work.
Then they sent me the photo.
It was perfect.
I liked it far more than any of the colours I'd shortlisted. They were equally enthusiastic, saying that although it was a flat paint, it really highlighted the Emira's curves and seemed to change character as the light caught it in different ways.
I must have opened that photo of the painted door a hundred times over the next week, trying to imagine the whole car finished in that colour. I genuinely couldn't wait to see it in the flesh.
Now, I fully appreciate this is going to be a very divisive colour. Some people are going to hate it. My girlfriend certainly does.
But I absolutely love it.
So... here it is.
At the very least, other drivers shouldn't be able to claim they didn't see me when they pull out in front of me...
The first week of June finally brought some excitement. Late on the Monday evening, I noticed via the tracker that my Emira had been moved out of storage and into Beaconsfield's workshop. Interesting...
The next day—conveniently lining up with my weekly "any news?" phone call (they must have been thoroughly sick of hearing from me by then)—I got some unexpected good news.
A large batch of parts had finally arrived. They'd already sent the van up to Silverstone a couple of times to collect them, and they could finally start putting my car back together. There were still a handful of parts missing, but those were expected the following week.
Beaconsfield also very kindly posted back the sunglasses I'd left in the Emira. Given the blazing UK summer we've been having, I'd actually been missing those more than expected.
With the rebuild underway, attention turned to finalizing the colour. We went backwards and forwards over several options, including Sun Glare Yellow, Inca Yellow (TR6), and TCX Blazing Yellow, the latter being my favourite at that point. The replacement paint had to be a solid (non-metallic) colour and also be compatible with the existing paint already on the car.
I resent some of the AI-generated images I'd created earlier using those colours to help make the final decision. I quickly discovered that AI is pretty useless for this sort of thing. It gives you a rough idea, but ask it to generate the same car in the same colour twice and you'll get two completely different shades. Great for inspiration, hopeless for choosing an actual paint colour.
However, the team at Beaconsfield looked at my favourite AI image and thought they could recreate the shade it was trying to emulate. Convinced they were onto something, they mixed up a batch of paint, grabbed one of the discarded Emira doors from their pile of blistered panels, and sprayed it as a test.
I hadn't asked them to do this—they simply had a hunch that the colour would work.
Then they sent me the photo.
It was perfect.
I liked it far more than any of the colours I'd shortlisted. They were equally enthusiastic, saying that although it was a flat paint, it really highlighted the Emira's curves and seemed to change character as the light caught it in different ways.
I must have opened that photo of the painted door a hundred times over the next week, trying to imagine the whole car finished in that colour. I genuinely couldn't wait to see it in the flesh.
Now, I fully appreciate this is going to be a very divisive colour. Some people are going to hate it. My girlfriend certainly does.
But I absolutely love it.
So... here it is.
At the very least, other drivers shouldn't be able to claim they didn't see me when they pull out in front of me...
OP
OP
- Thread starter
- #28
I realise that this journal has ended up being more about the paint than the rebuild - but I promise there will be more about the rebuild when I get round to writing up the next post.
That is an amazing yellow. That is going to look good. If its a full custom color make sure you get a copy of whatever color information they used to create it so you can get it recreated in the future just in case.
@geoffbland
I appreciate you taking the time to document your repair experience. One of my concerns about purchasing an Emira was the amount of down-time likely in the event of collision damage. It sounds like your car is in good hands, and that they are doing the best they can given the parts shortage. That seems to be a world-wide problem with almost all brands. I waited months for trim pieces that fell off because they were improperly glued during assembly on a brand new Hyundai Telluride, which happened on many of them built during that MY, and that was a high volume model. Parts shortages are also affecting C8 (Corvette) repairs in the US.
I hope the minor bits you need to complete your repair arrive soon and look forward to future updates.
I appreciate you taking the time to document your repair experience. One of my concerns about purchasing an Emira was the amount of down-time likely in the event of collision damage. It sounds like your car is in good hands, and that they are doing the best they can given the parts shortage. That seems to be a world-wide problem with almost all brands. I waited months for trim pieces that fell off because they were improperly glued during assembly on a brand new Hyundai Telluride, which happened on many of them built during that MY, and that was a high volume model. Parts shortages are also affecting C8 (Corvette) repairs in the US.
I hope the minor bits you need to complete your repair arrive soon and look forward to future updates.
can you make a mold from them?
OP
OP
- Thread starter
- #32
I wish. But no, all body shops at least official ones in the UK are instructed to destroy all the faulty panels, they won't allow a customer to have them back. It seems a bit silly as if anyone were serious about making their own replacement they would just use the door they had on their car already.
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OP
OP
- Thread starter
- #33
Mid June
With all the parts finally in, Beaconsfield now completed the rebuild of the front end.
It's actually quite fascinating seeing the car in this state because you can clearly identify everything that was damaged in the accident—the brand-new shiny parts are a bit of a giveaway. More importantly, you can also see what didn't need replacing.
The front aluminium chassis remained completely original and undamaged. Both the front subframe and even the front crash bar are untouched. The upper plastic bumper support wasn't so lucky, and most of pipework, wiring and brackets above the radiators also had to be replaced.
The passenger side (on this UK car) took the brunt of the impact, so all of the front wing supports on that side are new. You'll also notice the redesigned front wing brackets—they look like a revised part and I'd imagine they're probably a little lighter too (Lotus style - must be worth an extra 10mph).
The wheels and front suspension was all undamaged. Also luckily the front wings pushed themselves out rather than straight back so the doors were untouched.
One thing that made me smile was seeing the Lotus recall-fitted rubber bib still hanging on in there, complete with the gaffer tape from my rather agricultural attempt to patch up all the cracks and holes. Ironically, the silicone sheet I'd ordered to make a proper replacement turned up just a couple of days after the accident. Typical timing.
There are still quite a few parts waiting to go back on when all the panels are reattached as you can see from the contents of the green boxes. And that innocent-looking cardboard box? I'm fairly sure that's a pair of new headlights...
...roughly £5,000 worth of headlights sitting in a cardboard box. Best not drop that.
One thing I've really appreciated throughout this repair is how Beaconsfield documented the rebuild for me so I can actually see what's been done at each step and check it has been done correctly. Rather than simply handing the car back fully assembled and saying "there you go". It's reassuring to see the attention to detail too—all the wiring looms, coolant hoses and pipework have been routed exactly as they should be (see Exotic Pulses video for the counter-example in the Emira he is restoring).
With the mechanical rebuild complete, it was finally time for the moment I'd been waiting for...
The respray.
First, the original Lotus paint was carefully masked and flatted back ready for blending in.
Then the primer went on.
And finally... the first coats of the new colour, already looking better than the Lotus factory robot paint job.
There's also a gel coat involved on top of the base coat, although I'm not entirely sure which stage this particular photo was taken at because it already looks pretty gloss.
Beaconsfield also suggested something I hadn't even considered—a gloss black roof, Black Pack style. They thought it would really complement the new colour, and initially I thought about it. But the more I looked at the colour, the more I realised I didn't want anything distracting from it. In the end I decided to keep the roof body-coloured, I think that's the right choice (owners of black pack cars may disagree).
I do still have one modification of my own waiting in the shed at home though.
My black Aerie wheels.
I've had them nearly a year now not fitted over winter. The original plan was to fit them after our Wales trip, swapping them over now winter was over (Wales was almost guaranteed to provide rain regardless of the season). Thanks to the accident they never got fitted, so when the car finally comes home they'll be going straight on for the first time.
Against this colour, I think they're going to look absolutely spot on.
With all the parts finally in, Beaconsfield now completed the rebuild of the front end.
It's actually quite fascinating seeing the car in this state because you can clearly identify everything that was damaged in the accident—the brand-new shiny parts are a bit of a giveaway. More importantly, you can also see what didn't need replacing.
The front aluminium chassis remained completely original and undamaged. Both the front subframe and even the front crash bar are untouched. The upper plastic bumper support wasn't so lucky, and most of pipework, wiring and brackets above the radiators also had to be replaced.
The passenger side (on this UK car) took the brunt of the impact, so all of the front wing supports on that side are new. You'll also notice the redesigned front wing brackets—they look like a revised part and I'd imagine they're probably a little lighter too (Lotus style - must be worth an extra 10mph).
The wheels and front suspension was all undamaged. Also luckily the front wings pushed themselves out rather than straight back so the doors were untouched.
One thing that made me smile was seeing the Lotus recall-fitted rubber bib still hanging on in there, complete with the gaffer tape from my rather agricultural attempt to patch up all the cracks and holes. Ironically, the silicone sheet I'd ordered to make a proper replacement turned up just a couple of days after the accident. Typical timing.
There are still quite a few parts waiting to go back on when all the panels are reattached as you can see from the contents of the green boxes. And that innocent-looking cardboard box? I'm fairly sure that's a pair of new headlights...
...roughly £5,000 worth of headlights sitting in a cardboard box. Best not drop that.
One thing I've really appreciated throughout this repair is how Beaconsfield documented the rebuild for me so I can actually see what's been done at each step and check it has been done correctly. Rather than simply handing the car back fully assembled and saying "there you go". It's reassuring to see the attention to detail too—all the wiring looms, coolant hoses and pipework have been routed exactly as they should be (see Exotic Pulses video for the counter-example in the Emira he is restoring).
With the mechanical rebuild complete, it was finally time for the moment I'd been waiting for...
The respray.
First, the original Lotus paint was carefully masked and flatted back ready for blending in.
Then the primer went on.
And finally... the first coats of the new colour, already looking better than the Lotus factory robot paint job.
There's also a gel coat involved on top of the base coat, although I'm not entirely sure which stage this particular photo was taken at because it already looks pretty gloss.
Beaconsfield also suggested something I hadn't even considered—a gloss black roof, Black Pack style. They thought it would really complement the new colour, and initially I thought about it. But the more I looked at the colour, the more I realised I didn't want anything distracting from it. In the end I decided to keep the roof body-coloured, I think that's the right choice (owners of black pack cars may disagree).
I do still have one modification of my own waiting in the shed at home though.
My black Aerie wheels.
I've had them nearly a year now not fitted over winter. The original plan was to fit them after our Wales trip, swapping them over now winter was over (Wales was almost guaranteed to provide rain regardless of the season). Thanks to the accident they never got fitted, so when the car finally comes home they'll be going straight on for the first time.
Against this colour, I think they're going to look absolutely spot on.
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!
With that said, seems you have a fantastic shop there, we should all be so lucky. I'm pretty sure nothing like that exists around where I live. And, short of the completely unfair insurance practices, you seem to have a great benefit of the loan car for many months and one where they try to match the level of your car. Definitely has me thinking (and now looking at my policy) to see where things stand with me in that regard.
Anyway, very glad to hear things seem to be working out well for you and know that you now have all of us on the edge of our seats waiting to see photos of your finished product!
Cheers,
Arrrghhh! I'm just now seeing your post and reading about your misadventure (and the many that followed). Sooo sorry this happened to you! Gut-wrenching for us to see your car in this state but as others have noted, very fortunate everyone was safe and well. after the accident.
With that said, seems you have a fantastic shop there, we should all be so lucky. I'm pretty sure nothing like that exists around where I live. And, short of the completely unfair insurance practices, you seem to have a great benefit of the loan car for many months and one where they try to match the level of your car. Definitely has me thinking (and now looking at my policy) to see where things stand with me in that regard.
Anyway, very glad to hear things seem to be working out well for you and know that you now have all of us on the edge of our seats waiting to see photos of your finished product!
Cheers,
OP
OP
- Thread starter
- #35
Thanks for the kind words. Yes, we do seem to be doing well with bodyshops in the UK, we not only have Beaconsfield Workshop (really top end as they normally do Rolls and Bentleys), there's also Specialised Paintwork (fibreglass experts) that have done amazing work on my Elise and Hilton and Moss that do some amazing restorations. But Beaconsfield were great with the door replacement on my Emira last year and have been great with these repairs - it's really nice to work with people that are genuinely enthused about the cars and the work they do.
I love this color!
OP
OP
- Thread starter
- #37
End of June
One thing worth mentioning is that, while Beaconsfield are rebuilding my car, they're also dealing with three or four Emiras every week needing replacement panels under warranty for panel blistering issues. Those jobs have to be turned around fairly quickly, so understandably these cars take priority.
I'm perfectly happy to wait a little longer if it means my car gets the attention it deserves. As long as I have my car back before the third week of July, my planned European road trip is still on. (Or, failing that, I still have enough time to cancel nearly everything before the refund expiry dates, hotels, ferries and the like.) That said, I also can't wait to see the finished car and have my Emira back again.
The good news is that all of the body panels are now painted—front and rear—I haven’t a photo with the bonnet resprayed but I assume it has been. The resprayed panels are the first real indication of what the finished car is going to look like.
One thing to bear in mind is that these photos are taken under the body shop's bright LED lighting. That tends to exaggerate the slight green tint in the paint, making it more noticeable than it is in natural daylight. (For anyone interested in the science, white LEDs are actually blue LEDs with a yellow phosphor coating, which tricks our eyes into seeing white light.)
The roof is now painted, and the engine cover is starting to go back together (well, apart from the bits sitting the passenger seat).
Then comes what is probably the most exciting stage so far...
The first test fit.
With the doors and rear hung back on, the car suddenly stops looking like a collection of painted panels and starts looking like an Emira again. Wow!
Subtle is one thing it is not. 
Check out how the colour is changing tint slightly under different intensities of lighting.
Although it looks almost finished in these photos, appearances are very deceptive. There is still a lot more that you might expect still left to do.
Both doors still need completely rebuilding internally. A lot of electrics need to be refitted front and rear. Every light, vent, grille, bracket, seal, trim panel, mirror, fuel cap, badge, decal, number plate etc. has to go back on. Then comes what is probably the most time-consuming part of the whole repair—adjusting every panel until all of the gaps are exactly right.
When Beaconsfield replaced my driver's door previously, it came back with panel gaps that were actually better than when the car left the factory. I also had the infamous issue of the rear bumper sticking out slightly on one side. My dealer's response was the traditional "They're all like that, sir." Beaconsfield quietly adjusted it and made it properly flush. So my expectations for this repair are understandably pretty high.
It’s worth remembering next time you take your Emira in for replacement panels – it’s a lot more than a quick old panel off, new panel on and respray.
And that's where things stand today.
You're now pretty much as up to date as I am. Tomorrow is my scheduled weekly phone call—by now it's probably become part of Beaconsfield's routine—and hopefully there'll be another batch of good news and progress to report next time.
One thing worth mentioning is that, while Beaconsfield are rebuilding my car, they're also dealing with three or four Emiras every week needing replacement panels under warranty for panel blistering issues. Those jobs have to be turned around fairly quickly, so understandably these cars take priority.
I'm perfectly happy to wait a little longer if it means my car gets the attention it deserves. As long as I have my car back before the third week of July, my planned European road trip is still on. (Or, failing that, I still have enough time to cancel nearly everything before the refund expiry dates, hotels, ferries and the like.) That said, I also can't wait to see the finished car and have my Emira back again.
The good news is that all of the body panels are now painted—front and rear—I haven’t a photo with the bonnet resprayed but I assume it has been. The resprayed panels are the first real indication of what the finished car is going to look like.
One thing to bear in mind is that these photos are taken under the body shop's bright LED lighting. That tends to exaggerate the slight green tint in the paint, making it more noticeable than it is in natural daylight. (For anyone interested in the science, white LEDs are actually blue LEDs with a yellow phosphor coating, which tricks our eyes into seeing white light.)
The roof is now painted, and the engine cover is starting to go back together (well, apart from the bits sitting the passenger seat).
Then comes what is probably the most exciting stage so far...
The first test fit.
With the doors and rear hung back on, the car suddenly stops looking like a collection of painted panels and starts looking like an Emira again. Wow!
Subtle is one thing it is not. Check out how the colour is changing tint slightly under different intensities of lighting.
Although it looks almost finished in these photos, appearances are very deceptive. There is still a lot more that you might expect still left to do.
Both doors still need completely rebuilding internally. A lot of electrics need to be refitted front and rear. Every light, vent, grille, bracket, seal, trim panel, mirror, fuel cap, badge, decal, number plate etc. has to go back on. Then comes what is probably the most time-consuming part of the whole repair—adjusting every panel until all of the gaps are exactly right.
When Beaconsfield replaced my driver's door previously, it came back with panel gaps that were actually better than when the car left the factory. I also had the infamous issue of the rear bumper sticking out slightly on one side. My dealer's response was the traditional "They're all like that, sir." Beaconsfield quietly adjusted it and made it properly flush. So my expectations for this repair are understandably pretty high.
It’s worth remembering next time you take your Emira in for replacement panels – it’s a lot more than a quick old panel off, new panel on and respray.
And that's where things stand today.
You're now pretty much as up to date as I am. Tomorrow is my scheduled weekly phone call—by now it's probably become part of Beaconsfield's routine—and hopefully there'll be another batch of good news and progress to report next time.
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OP
OP
- Thread starter
- #38
Seeing the Emira 420.
Resisting the overwhelming temptation to ask Beaconsfield if the seat back could be resprayed a matching yellow.
Resisting the overwhelming temptation to ask Beaconsfield if the seat back could be resprayed a matching yellow.
Regarding the black pack
Wow. We're definitely going to see you coming in this!End of June
One thing worth mentioning is that, while Beaconsfield are rebuilding my car, they're also dealing with three or four Emiras every week needing replacement panels under warranty for panel blistering issues. Those jobs have to be turned around fairly quickly, so understandably these cars take priority.
I'm perfectly happy to wait a little longer if it means my car gets the attention it deserves. As long as I have my car back before the third week of July, my planned European road trip is still on. (Or, failing that, I still have enough time to cancel nearly everything before the refund expiry dates, hotels, ferries and the like.) That said, I also can't wait to see the finished car and have my Emira back again.
The good news is that all of the body panels are now painted—front and rear—I haven’t a photo with the bonnet resprayed but I assume it has been. The resprayed panels are the first real indication of what the finished car is going to look like.
View attachment 84052
View attachment 84053
One thing to bear in mind is that these photos are taken under the body shop's bright LED lighting. That tends to exaggerate the slight green tint in the paint, making it more noticeable than it is in natural daylight. (For anyone interested in the science, white LEDs are actually blue LEDs with a yellow phosphor coating, which tricks our eyes into seeing white light.)
The roof is now painted, and the engine cover is starting to go back together (well, apart from the bits sitting the passenger seat).
View attachment 84054
Then comes what is probably the most exciting stage so far...
The first test fit.
With the doors and rear hung back on, the car suddenly stops looking like a collection of painted panels and starts looking like an Emira again. Wow!
View attachment 84055
Check out how the colour is changing tint slightly under different intensities of lighting.
Although it looks almost finished in these photos, appearances are very deceptive. There is still a lot more that you might expect still left to do.
Both doors still need completely rebuilding internally. A lot of electrics need to be refitted front and rear. Every light, vent, grille, bracket, seal, trim panel, mirror, fuel cap, badge, decal, number plate etc. has to go back on. Then comes what is probably the most time-consuming part of the whole repair—adjusting every panel until all of the gaps are exactly right.
When Beaconsfield replaced my driver's door previously, it came back with panel gaps that were actually better than when the car left the factory. I also had the infamous issue of the rear bumper sticking out slightly on one side. My dealer's response was the traditional "They're all like that, sir." Beaconsfield quietly adjusted it and made it properly flush. So my expectations for this repair are understandably pretty high.
It’s worth remembering next time you take your Emira in for replacement panels – it’s a lot more than a quick old panel off, new panel on and respray.
And that's where things stand today.
You're now pretty much as up to date as I am. Tomorrow is my scheduled weekly phone call—by now it's probably become part of Beaconsfield's routine—and hopefully there'll be another batch of good news and progress to report next time.
I'm glad something good seems to be coming out of a crap situation for you. Fingers crossed this is ready for the road trip
As you have had the roof off, are you able to confirm either way if its structural
I am so hoping Lotus pull their finger out and offer a Targa option at some point, or maybe someone else will and its a straight swap.
I am so hoping Lotus pull their finger out and offer a Targa option at some point, or maybe someone else will and its a straight swap.
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