Paint blistering issue update

[Hethel Merman]

Lotus UK have been building composite body cars for decades, they even build half the panels on the Emira. They are very experienced with composites and have dealt with many of the issues over the years.
What are the chances that a company with this knowledge would not know exactly what the problem is, especially with having access to the failed panels?
Technically there's no reason that Lotus don't make all the panels on the Emira. For non-technical reasons they don't.
There may be non-technical reasons why they can't disclose what the issue is or step in and fix the issue.

One problem might be that long ago they repurposed their laminating facilities and laid off all the engineers and craftsmen associated with it. There was once a time when Lotus were world leaders in automotive composite panels and made parts for other companies, such as Aston Martin.
I understand they used to make their body shells using a Vacuum Assisted Resin Injection process back in their heyday, which might have minimised gas/air bubbles.

 

[geoffbland]

Such the tease. Surely there's a way you can directionally steer us to a "possible" "non-technical reason" for why this hasn't been resolved. Come on, throw us poor old dogs a bone.

I'm not teasing. I'm just stating facts and evidence already posted many times in this forum and drawing a conclusion from them. You can draw your own conclusions in the same way and extrapolate.

 

[geoffbland]

One problem might be that long ago they repurposed their laminating facilities and laid off all the engineers and craftsmen associated with it. There was once a time when Lotus were world leaders in automotive composite panels and made parts for other companies, such as Aston Martin.
I understand they used to make their body shells using a Vacuum Assisted Resin Injection process back in their heyday, which might have minimised gas/air bubbles.

Not just world leaders in automotive composite panels but in aviation too (and bikes). They were instrumental in helping get Scaled Composites in the US off the ground (literally). https://www.britishaviation-ptp.com/Companies/A/aviation_composites.html

Lotus still make automotive composite panels at Hethel I believe, they still make many of the panels on the Emira. Some work is outsourced to Creative Composites whom Lotus have worked with for many years (on the Exige for example) and as we know some work is now outsourced to Teijin for the Emira panels.

 

[Tobiasz17azs]

Today, I attended the show, and I’m not even sure if the owners are aware of the paint issues. There were five Emiras, and two of them had bubbling paint.

 

[3PFan]

Doors are available here as well
https://www.lotuspartsonline.com/p/147801583/8890572608.html

 

[scv]

(see prior posts above for additional context) I've decided to sell the new driver side Emira door Lotus provided me -- it's still sitting in the unopened OEM box (shipping pallet removed) -- I'm near Raleigh, NC for pick up or willing to deliver within reason for an agreed upon fee. $1200 for the door. My repair is a few months old, re-applied PPF 3 weeks ago --- you'd never never know the door was repaired and re-pained, it's spot on.
https://www.lotuspartsonline.com/p/147801583/8890572608.html

Good to hear @ 4months post repair. If repair holds/any setback with further time, update would be greatly apreciated

 

[geoffbland]

One problem might be that long ago they repurposed their laminating facilities and laid off all the engineers and craftsmen associated with it. There was once a time when Lotus were world leaders in automotive composite panels and made parts for other companies, such as Aston Martin.
I understand they used to make their body shells using a Vacuum Assisted Resin Injection process back in their heyday, which might have minimised gas/air bubbles.

I missed this when posted. Lotus still make composite panels - they make the bonnet, front wings and roof of the Emira. These are made Lotus Advanced Structures in Hethel, they got a new factory in 2023. I'm not sure if they also still use Creative Composites too - they use to make several panels for the Elise and Evora (don't confuse Lisburn, N.I. with Lisborn and think these are Teijin in Portugal).
They still use vacuum resin injection for these as far as I know - they learnt a lot over the years from early issues on the Elise and Evora.

Teijin make the doors, rear quarters and engine cover - these are panels with the blistering problems discussed here.

 

[Nelumbo nucifera]

I missed this when posted. Lotus still make composite panels - they make the bonnet, front wings and roof of the Emira. These are made Lotus Advanced Structures in Hethel, they got a new factory in 2023. I'm not sure if they also still use Creative Composites too - they use to make several panels for the Elise and Evora (don't confuse Lisburn, N.I. with Lisborn and think these are Teijin in Portugal).
They still use vacuum resin injection for these as far as I know - they learnt a lot over the years from early issues on the Elise and Evora.

Teijin make the doors, rear quarters and engine cover - these are panels with the blistering problems discussed here.

Thanks so much, Geoff, for that insightful information. That is very interesting. We would hope by now, Lotus - Teijin have woken up to what is going on and could potentially save themselves zillions in fault claims by eating humble pie talking to and, if they have any wisdom, re-engaging those who know best practice.

 

[3PFan]

Here's an update -- my attempt at repairing the door appears to have failed - it's started showing signs of the same blistering roughly 3 months after being completed and PPF'd -- the replacement door is being installed, apparently there's no fixing the original issue (per Lotus USA) and replacement is the best resolution.

 

[geoffbland]

Here's an update -- my attempt at repairing the door appears to have failed - it's started showing signs of the same blistering roughly 3 months after being completed and PPF'd -- the replacement door is being installed, apparently there's no fixing the original issue (per Lotus USA) and replacement is the best resolution.

Thanks for letting us know - that will be very useful for other owners here to confirm that replacement is the best fix and repairing the panels does not last.

It was certainly worth a try to repair the panels, shame it didn't work for you.

 

[seriously]

Here's an update -- my attempt at repairing the door appears to have failed - it's started showing signs of the same blistering roughly 3 months after being completed and PPF'd -- the replacement door is being installed, apparently there's no fixing the original issue (per Lotus USA) and replacement is the best resolution.

That’s good bad news. Thanks for sharing.

 

[Sanguineous]

Been a long time since I saw any post regarding paint blistering... Many 2025 and 2026 models have been delivered since, have you guy heard anything regarding the issue; is it less common on the newer models?

 

[geoffbland]

have you guy heard anything regarding the issue; is it less common on the newer models?

No it's not as far as we can tell. Obviously the newer the car the less time the issue has to show up so it's a bit difficult to judge but new cars do seem to be just as affected.

 

[bhavz]

It’s still a thing, mine went in for an assessment and there was a brand new unregistered purple emira waiting on panels to be replaced. Before it could go on sale.

 

[freefall_junkie]

It beggars belief that Lotus haven't got on top of this issue almost 4 years into production. Total incompetence and a perfect way to trash the name of your company and brand.

 

[Sanguineous]

It beggars belief that Lotus haven't got on top of this issue almost 4 years into production. Total incompetence and a perfect way to trash the name of your company and brand.

Well they did reduce the warranty period on paint... So they did something!

 

[EGTE]

Hi guys,
Does this help? McLaren specialists Thorney Motorsports claim to have found the cure for the corrosion issues:

 

[Foosh]

Hi guys,
Does this help? McLaren specialists Thorney Motorsports claim to have found the cure for the corrosion issues:

The Lotus panel problem is not a "corrosion" issue, it's not a "paint blistering" issue, and none of the panels are aluminum, which is the subject of the video. The Lotus problem is with the composite panels, most often the doors, which apparently come from a Chinese supplier. They cannot corrode, but fiberglass composite panels can blister, a problem usually caused by moisture trapped under the surface or chemical reactions within the laminate layers.

It appears that something changed starting with the '24 MY, because the blistering reports from 2024 and later MYs is down to about 10% or less, per more recent forum polls.

 

[Steve Tillett]

It's not a "corrosion" issue and it's not a "paint blistering" issue, and none of the panels are aluminum, which is the subject of the video. The Lotus problem is with composite panels underneath the paint. They cannot corrode, but fiberglass composite panels can blister, a problem usually caused by moisture trapped under the surface or chemical reactions within the laminate layers.

It appears that something changed starting with the '24 MY, because the blistering reports from 2024 and later MYs is down to about 10% or less.

As Foosh says, not an aluminium panel. It's also not moisture or a chemical reaction. It's simply being compression moulded with air left inside. The door handle feature traps this air which is why the doors are the worst panel. These bubbles are then under compression, trapped in as it's cured and eventually they work their way our. We have never had one moulding ever do this, but then we do not compression mould. our composites.
My latest doors are fine that were replaced this time last year, and the previous two pairs showed problems after nine months, if that is any comfort.

 

[EGTE]

Okay fair enough. I didn't realise it wasn't Aluminium.