Subaru LEGACY 2004 Service Manual page 563

Process
Process name
No.
9 Welding
10 Sanding (II)
11 Masking
Cleaning/ degreas-
12
ing
13 Primer coating
14 Leave unattended
Primer surfacer
15
coating
Front Bumper
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
(1)
(1) Welding rod
(2) Melt hatched area
(3) Section
NOTE:
• Melt the sections indicated by hatched area.
• Do not melt the welding rod until it flows out, in order to provide strength.
• Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
• Leave the welded spot unattended until it cools completely.
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
Sand the welded spot smooth with #240 sand paper.
Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply coat of primer at a spraying pressure of 245 — 343 kPa (2.5 — 3.5 kg/cm
— 50 psi) with a spray gun.
Leave the repaired area unattended at 20"C (68"F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth with alcohol. (Do not
use thinner since the coated area tends to melt.)
Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:
• UPS 300 Flex Primer
• No. 303 UPS 300 Exclusive hardener
• NPS 725 Exclusive Reducer (thinner)
• Mixing ratio:
2 : 1 (UPS 300 : No. 303)
• Viscosity: 12 — 14 sec./20"C (68"F)
• Coating film thickness: 40 — 50 #
EI-35
EXTERIOR/INTERIOR TRIM
Job contents
(2)
(3)
(2)
EI-00237
EI-00042
2
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