The repair of the 135R continues. A lot of work, but we are getting to the point of building instead of stripping. This is a video out of a series. Please feel free to comment as I love to hear from you.
**** WARNING****
Be very careful when removing the cashbox, so that the aluminium structure does not get scratched or damaged during the process. You will see some tools used, like the chisel and heath gun… those are used very shortly yo get it going and the way in. The blade on the vibrating saw is dull, so don’t use a sharp one on the alu side, there are many more good tips and recommendations in the comments . I recommend to read them before removing the crash box. I did use extreme care, and some actions maybe not emphases the needed care. For preparation of the new cashbox, please refer to video covering that part.
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The proper term is oscillating saw.
Some of the very experienced Lotus guys can get the crash boxes off as one piece without damage (for example if the rear of the car has taken the impact). Then the crash structure can be re-used again. Heat, chisels, wire etc seems to be how they do it, the tricky part is convex part at the top of the chassis, where the concave part of the crash structure mates to it – Beta Seal bonds 3 sides of the box section, so access is difficult.
Which alternative to betaseal are you planning on using?