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When I first saw Elan SEs driving around Norfolk, I promised myself, “One day I’ll have one.” Decades later, I made that dream a reality. Lotti has been with us for eight years now, bringing both joy and challenges.
The Challenge of Restoring Modern Classics
Owning a modern classic like the Elan SE comes with its share of hurdles, especially when it comes to sourcing parts. While many components were mass-produced and remain accessible, a significant number of model-specific parts have become scarce—or are no longer available.
A prime example is the door, window, and soft-top seals. While some have been reproduced in small batches by specialists, most are out of production. The original fittings were not particularly effective, and the manufacturing processes used for them are now obsolete. 3D printing to the rescue!
Replacing the Door Seals with 3D Printing
On Lotti, the passenger-side door seal was still intact, featuring a sponge-like core with a plastic outer coating. However, the driver-side seal had completely disintegrated. A fellow enthusiast helped source custom seals for the door, but certain areas—particularly the top and rear—still needed attention. I saw potential in using TPU (thermoplastic polyurethane) for this project.
In the absence of drawings, the workflow I adopted was to design replacement parts from scratch and print them at home using TPU materials. Once the design was finalized, I turned to Xometry for more advanced manufacturing services to produce precise, durable seals with a superior finish.
Improving the Original Design
Interestingly, the original seal design didn’t fully serve its purpose. My new design avoids these shortcomings while allowing for customization. I divided the seal into three parts to accommodate the constraints of home 3D printing. This modular approach also benefits other Elan owners, as each car varies slightly, and the parts can be tailored without a complete redesign.
The parts pictured below demonstrate the fit with the window trim and rear door trim. Xometry produced these components using TPU and the Selective Laser Sintering (SLS) process. I plan to test additional iterations and produce parts using Xometry’s HP Multi Jet Fusion (MJF) process for an even better finish. I’m aiming for something that matches the finish on the original seals as far as possible with sufficient flexibility to make a weatherproof fit. There are also some other elements of the seals that are wearing so the next step will be to consider how best to replace those.
The modular parts—designed for easy assembly—precisely match the Elan’s mounting holes. One part bolts to the end of the door, another interfaces with the outer door seal, and the third covers the inner door card cutout.
Showcasing Innovation: 3D Printing at the NEC Classic Car Show
The Elan with prototype parts was exhibited on the Lotus Drivers Club stand at the Classic Car exhibition at the NEC, Birmingham in November 2024. The 3d printing for parts generated a great deal of attention—and it was interesting to hear some comments from those in the auto industry about how it was used in mainstream manufacturing.
Learn more about the Lotus Drivers Club: https://www.lotusdriversclub.org.uk/ and https://www.facebook.com/groups/18414574095
Have you used 3D printing for restoring classic cars or solving unique challenges? Share your experiences, ideas, or questions about innovative restoration methods!
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