Pontiac Fiero 1988 Service Manual page 132

BODY PANEL REPAIR 2C-1
SECTION 2C
BODY PANEL REPAIR
CONTENTS
General Description
2C-1
" E n d u r a f l e x " Panel Repair
2C-1
Paint Repair . . 2C-2
Nonflexible Panel Paint Repair 2C-2
Partial (Spot) Repair
2 C - 2
Full Panel Paint Repair
2C-3
Flexible Panel Paint Repair .
2 C - 4
Federal Vehicle Theft Prevention Standard . . . . . 2C-5
GENERAL DESCRIPTION
This section describes how to repair body
panels, both for structural and surface repairs. Paint
repair for the basecoat/clearcoat paint system is also
covered.
In many of .the following procedures, a particu-
lar brand of material may be mentioned. In all cases,
equivalent products from other suppliers may be used.
"ENDURAFLEX" PANEL REPAIR
The following information details the procedure
to be used for the repair of "Enduraflex
,,
panels when
structural integrity must be restored. The bumpers,
doors, fenders and lower rear quarters use this
material.
1. Remove affected panel where applicable. In
many cases, repair may be accomplished with-
out removal of the part.
2. Clean area(s) to be repaired with a wax, grease
and silicone removing solvent applied with a
water-dampened cloth. On structural-type repair
it will also be necessary to clean the underside
of the repair area. Wipe dry, then sand the sur-
face about 40mm (1 1/2") away from each side
of the break with a #50 grit disc.
3. Align and secure the piece on the faceside of the
part with two inch body sealing tape. Use a
lightweight clamp, if necessary, to align joint.
4. Cut two pieces of fiberglass cloth large enough
to overlap the break 40mm (1 1/2"). Cut only to
length required.
5. On a clean, flat surface of nonporous material
such as a metal, glass or plastic pallet, deposit
equal length beads of each component (3M
Flexible Parts Repair Materials #05900 or
equivalent). With a paddling motion, mix the
two components until a uniform color and con-
sistency is achieved.
6. Apply a layer of the mixture approximately
3mm (1/8") thick on the backside of the panel
overlapping the break at least 40mm (1 1/2").
7. Apply one piece of the pre-cut fiberglass cloth
to the applied adhesive and cover the cloth with
additional adhesive. Apply the second piece of
the pre-cut fiberglass cloth to the adhesive and
immediately cover the cloth with additional
adhesive in sufficient quantity to fill the weave.
8. Allow 20-30 minutes cure time at 16° to 2 7 ° C
(60° to 80°F). Trim excess repair material at
edge if necessary.
Repair the faceside of the panel using the fol-
lowing procedures:
1. Clean topside of panel with a wax, grease and
silicone removing solvent applied with a water
dampened cloth. Wipe dry.
2. With a random orbit sander fitted with a #180
grit disc, remove the total paint film in and sur-
rounding the area(s) to be repaired. The repair
material should not overlap the painted surface.
3. With a drill motor and a 3" # 5 0 grit disc or as an
option, a rotary file, cut a "Vee" along the break
line approximately 13mm (1/2") wide. Remove
all dust and loose particles from the repair area.
4. Mix and apply the repair material. Apply a light
coat first over the damage; then continue appli-
cation to a level slightly above the surrounding
contour.
5. Allow the applied mixture to cure 20 to 30 min-
utes at 16° to 27°C (60°-80°F).
6. Establish rough contour, where possible, with a
curved tooth body file. If low areas or pits
remain, mix and apply additional adhesive.
7. Block sand using #220 grit sandpaper to estab-
lish accurate level and contour with the sur-
rounding surface.
8. For final feathering, use a random orbit sander
with a #320 grit disc. See paint repair proce-
dures below.
Below is a list of typical equipment and material
necessary to perform the above described repair
procedures.