Lotus Europa Community

Next question: I cut the stop washers that keep the windows from going down very far. But now the windows are in danger of breaking through the bottom of the door. Has anyone bent the curved window tracks to give more clearance? And if so, how? I'm thinking of cutting a tighter curve through a 2x4, then clamping it to each of the lower legs of the track to increase their curvature slightly. It doesn't need much.

I thought you had a rusty seat frame. Did I misremember?

First, in case you aren't aware, there are two different hinge systems to choose from. r.d. enterprises has stainless steel reproductions of the original hinge. Lotus Supplies has a completely different arrangement (https://www.lotus-supplies.com/parts/bodywork/fittings-bodywork/door-hinge-brass-per-door/)

I only have experience with the Lotus Supplies hinge so I can't compare which is easier to adjust (I don't think either are easy) but the Lotus Supplies system allows you, once you have adjusted the door, to take it off and put it back on and only require a vertical adjustment to get back where you were. Does that make sense?

I'm not sure what you mean by hanging the door without hardware. I'm guessing that you want to trial fit an empty door shell, then assemble the door and be able to put it back the way it was without sagging. The Lotus Supplies hinges will allow you to do that but the r.d./Lotus hinges will not. Sagging will not be an issue with the Lotus Supplies hinges assuming you've tightened the body parts of the hinges sufficiently. For what it's worth, I don't think the weight of the door is significant when adjusting it. What would be really helpful is a trained monkey who can sit in the car and tighten the hinges when the door is positioned where you want it. I don't know if you can still get a trunk monkey (https://www.youtube.com/results?search_query=trunk+monkey+commercials) but if you can, they seem pretty resourceful! 

As far as disassembling the window lift mechanism to clean the motors, I've done it several times. The only thing to keep in mind is that the arm is spring loaded so be sure you have a good grip on it so it doesn't get away from you. The motor is sealed from the weather. I took one of mine apart. My advice is if your motors are working to leave them alone. If they aren't working well, you can open them up and investigate but you might want to just buy replacements. They are GM items and I think they are still available from places like NAPA. Or you can try a more modern motor described here (https://www.lotuseuropa.org/LotusForum/index.php?topic=971.msg7591#msg7591).

Are drawings with dimensions available?

Pretty sure the locking bolt is 6mm x 1.0.  Lightly snug, do not tighten it down hard!