📓 Journals Crash and Panel Blistering Repair

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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.
They didn't take the roof off. That's the only original panel left now on my car.

Is it structural - that depends? The roof panel is just fibreglass so weak in compression and bending, that support is provided by the three pressed aluminium body shell parts around the door and forming the roll hoop behind the seats. But the roof is glued between these pieces and fibreglass is tough to pull apart so provides a lot rigidity against shear and tension between these body parts. I guess it all works together. But don't trust me I'm not a car safety designer.
 
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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! 😋 Subtle is one thing it is not. 😎

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.
Wow, Beaconfield looks amazing. I doubt there's any shop in the US with anywhere close to their extensive experience and expertise on all aspects of the Emira.

I am lucky to have an indy shop called Eclectic Motor Company (north of Baltimore, MD US) that specializes in all types of vintage cars. They use the same of model of documenting everything with video and still pictures and sending weekly reports. They completely restored and transformed a vintage Mini Cooper for me, turning into a car that was far better than it was when it left the factory. Out of warranty, that's where my Emira will go.

IMG_3993.webp
 
Wow. We're definitely going to see you coming in this! 😄
That's the plan! No-one will pull out again on me if they see me coming.
 
You're making the assumption they look first
I know - I can but hope...
My Emira could have been bright yellow with neon green spots and pink stripes - I expect the driver still would have pulled out on me, they just didn't even look.

This was not the first time someone has pulled out on me.. but that is another (very long) story...
 
Seeing the Emira 420.

View attachment 84060

Resisting the overwhelming temptation to ask Beaconsfield if the seat back could be resprayed a matching yellow.

Got to say, as you’ve gone for a unique stand out colour, I’d go for it. Have them paint the Lotus on the top of the engine your yellow too?

Do Silverstone Lotus use this body shop in Beaconfield every time? Whilst I use the ex-Lotus dealers in Nottingham for my servicing (who I can heartily recommend and who remain an official Lotus service and repair centre), if I ever need replacement panels, may consider Silverstone who are my closest official dealer living just north of Leicester. Based upon your experience as so many paint shops aren’t so impressive.
 
Got to say, as you’ve gone for a unique stand out colour, I’d go for it. Have them paint the Lotus on the top of the engine your yellow too?
Way ahead of you --> https://www.emiraforum.com/threads/what-did-you-do-to-your-emira-today.4043/post-183720

But it don't think I'm going to do this for now. I just want my car back.

Do Silverstone Lotus use this body shop in Beaconfield every time? Whilst I use the ex-Lotus dealers in Nottingham for my servicing (who I can heartily recommend and who remain an official Lotus service and repair centre), if I ever need replacement panels, may consider Silverstone who are my closest official dealer living just north of Leicester. Based upon your experience as so many paint shops aren’t so impressive.
Yes, all the Lotus Silverstone ones go there as well as the ones from a few other dealerships. These days there's only a few "official" body shops that Lotus will allow the warranty work to be done at. If nothing else they are hugely experienced with Emiras having worked on close to a 1,000 of them now.

Also I will mention this again - Beaconsfield will do a free inspection for anyone worried about the blistering problem on your Emira. It sometimes can be difficult to spot especially when it first starts, if your 3 years is close to up I can't see a reason why you wouldn't have the inspection done (even though your warranty is longer than 3 years in reality).
 
Start of July

A quick update this time after speaking to Beaconsfield this morning.

The rear of the car from the doors back is all buttoned up and complete. They are now waiting for the glass to be fitted back into the car on Thursday and then they will then complete the front and the rest of the car.

Assuming nothing unexpected happens, I will have my Emira back end of next week.

I will be counting down the days…
 
Start of July #2

I spoke with Beaconsfield Workshop again today, it is taking a little longer than expected and I'm not going to have the car back next week but hopefully the week after, not least because they need fit PPF to the front of the car and to take it elsewhere to have the air-con refilled. They were very apologetic about this - but fine by me, I'm happy for them to take a bit longer if it means the work is not rushed.

They confirmed all the panels are now painted and ready to go back on. Here's the bumpers and bonnet being sprayed.

Top coat on panels 3.webp


The back is now complete and all components back in place, the doors are on although the door panels still need fitting. All the car's glass is being fitted this morning and then they can get all the panels back on and start adjusting the panel gaps.

Here's the a photo of test fit of the bonnet from a day or two ago, you can see all the remaining pieces still to be fitted. When I first saw this I thought that the Emira next to mine was orange - it took me a second to realise that this is Hethel Yellow, my original colour.

Top view deside Hethel Yellow.webp
 
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Start of July #2

I spoke with Beaconsfield Workshop again today, it is taking a little longer than expected and I'm not going to have the car back next week but hopefully the week after. They were very apologetic about this - but fine by me, I'm happy for them to take a bit longer if it means the work is not rushed.

They confirmed all the panels are now painted and ready to go back on. Here's the bumpers and bonnet being sprayed.

View attachment 84275

The back is now complete and all components back in place, the doors are on although the door panels still need fitting. All the car's glass is being fitted this morning and then they can get all the panels back on and start adjusting the panel gaps.

Here's the a photo of test fit of the bonnet from a day or two ago, you can see all the remaining pieces still to be fitted. When I first saw this I thought that the Emira next to mine was orange - it took me a second to realise that this is Hethel Yellow, my original colour.

View attachment 84277
Looking good. The difference next to Hethel Yellow really messes with your head!
 
Start of July #2

I spoke with Beaconsfield Workshop again today, it is taking a little longer than expected and I'm not going to have the car back next week but hopefully the week after. They were very apologetic about this - but fine by me, I'm happy for them to take a bit longer if it means the work is not rushed.

They confirmed all the panels are now painted and ready to go back on. Here's the bumpers and bonnet being sprayed.

View attachment 84275

The back is now complete and all components back in place, the doors are on although the door panels still need fitting. All the car's glass is being fitted this morning and then they can get all the panels back on and start adjusting the panel gaps.

Here's the a photo of test fit of the bonnet from a day or two ago, you can see all the remaining pieces still to be fitted. When I first saw this I thought that the Emira next to mine was orange - it took me a second to realise that this is Hethel Yellow, my original colour.

View attachment 84277.
Wow, what a difference, quite a range of shades of "yellow". But did your car grow?! From this perspective your car looks so much longer than the Hethel Yellow!
Have to say though I wouldn't be so happy to see that body panel resting on my roof!
 
Wow, what a difference, quite a range of shades of "yellow". But did your car grow?! From this perspective your car looks so much longer than the Hethel Yellow!
Have to say though I wouldn't be so happy to see that body panel resting on my roof!
Yes, I had it converted to an Emira Limousine whilst I was at it. :)
But yeah that's a bit weird isn't it, just a trick of the perspective as I think mine is up on stands. If you follow the line of the bottom of the back of my car to the tyre to the front of the other car they are the same.
 
6th July

Not much of an update this time but Beaconsfield Workshop texted me and asked if I wanted to have my wheels redone, as they thought gloss black wheels would suit the car better with the brighter colour than the diamond cut ones.

This was something I had been planning anyway as I also don’t really like the diamond cut wheels on any car, they look a bit tacky on the Emira to my eyes. Also, I had kerbed the passenger side wheels (twice) thanks to narrow car park entrances in Europe trying to get close to the pay machine so the passenger could pay. I was going to send the existing (Winter) wheels off for a refurb and power coating once I had stuck on the new (Summer) Aerie wheels. But Beaconsfield Workshop gave me a price I couldn’t refuse for doing this – plus it’ll save me a load of time and effort carting the wheels around myself.

But again, it does show that Beaconsfield are invested in the car and want it to look its best.

I hope to have more news later in the week (and hopefully some more pictures).
 
I so want to see this in the flesh/metal/fibreglass/composite :)
Happy for you that it seems to be coming together.
 
I agree that the black wheels will look better on a yellow Emira as that's what I did, although I bought a new set of OEM wheels and kept the diamond cut ones.

One thing to note and previously mentioned are you changing the nose badge to black?

When my original badge got a stone chip I tested it with a black badge and liked it better.

With your new yellow being potentially a close match to the yellow on the badge it might not look so good especially if it's slightly different.

I can't wait to see this car when it gets released into the wild!

2025-03-04 Nose Badge Ding.webp
IMG_20250502_132946.webp
 
http://colinchapmanmuseum.co.uk/?page_id=2213

As far as I know the original badges were just stamped into the metal bodies of the cars. The Yellow/Green ones were the first enamelled badges. The black badge was introduced later after Jim Clark's death as a mark of respect. A new simplified badge with non-serif fonts was introduced with the Emira.

Lotus Badges.webp

Credit: Colin Chapman Museum

A printed badge on an early Lotus 6 - note the LOTUS is sans-serif on very early cars too:

1783529930039.webp
 
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