Fiat 500 Collision Awareness Manual page 35

2012 FF
Preparation:
1. Belt cut skins will require determining and cutting of
the sectioning locations on the original panel and on
the replacement panel.
2. Remove the door skin by grinding the outer edge (C)
until the seam is perforated.
3. Cut around weld nuggets and spot welds with a spot
weld cutting bit or similar weld removal tool.
4. If panel is attached with adhesive you may use heat,
from a non­flame heat source, up to 204°C. (400F°).
This will aid in loosening the bond.
5. With an air chisel and a flat bladed bit, remove outer
skin and any remaining hem flange.
6. Grind any remaining weld nuggets flush with door
frame, and remove all adhesive, paint, E­coating and
corrosion protective coatings from the area where
the structural adhesive will be applied, and where
the 'butt­joint" is to take place. The metal should be
completely bare and shiny in appearance, if the metal
appears pewter in color all of the galvanized coating
has not been removed.
7. Straighten door flange and any remaining damage on
door shell using the hammer and dolly method.
8. The area of the new door skin that will make contact
with the door shell will need to be scuffed with a
course abrasive pad or ground with a 50 grit grinding
disc. This will vary upon adhesive manufacturers, be
certain to check adhesive manufacturer recommen­
dations.
9. Dry fit the new panel.
clamps to hold the panel in place, as necessary.
CAUTION: Be certain the fit is good from the skin to door and door to door opening. Cured adhesive is extremely
strong and will not allow for "adjustments".
10. Without a mixing tip attached, purge a small amount of structural adhesive from the cartridge. This will ensure an
even flow of both components.
11. Attach a mixing tip and dispense a mixing tube's length of adhesive from the cartridge.
NOTE: Refer to the structural adhesives manufacturer for information on work, handling and curing times.
Installation:
NOTE: Do not apply adhesive within 25mm. (1in.) of the belt cut location.
12. Apply a 10 ­ 13mm. (3/8 ­ 1/2 in.) bead of structural adhesive to bare metal mating surfaces. Use a body filler
applicator to level the adhesive, making sure to cover all bare metal to protect against corrosion.
NOTE: When applying adhesives be certain any and all drain holes remain open and clear of obstructions.
13. Apply a second bead of adhesive to ensure proper bead thickness.
14. Position the new panel. If repositioning is necessary slide the panel, do not lift or separate panels. Adjustments
must be made by sliding, not lifting the panel(s). Apply clamps to hold panel in position, as necessary.
NOTE: There are many tools readily available to aid in the hem flange folding process.
15. Roll the hem flange over. Remove excess adhesive. This will save time, as compared to waiting until cured.
16. Re­check door gap and flushness to the vehicle opening and adjust as necessary.
17. Allow the adhesive to cure per manufacturer recommendations. When fully cured, expect the adhesive to be a little
tacky, as this is a normal characteristic of the adhesive. Remove clamps, if used.
18. Remove any excess cured adhesive with a grinder or abrasive disc. All adhesive must be removed from the cosmetic
repair area to ensure proper adhesion of repair and refinish materials.
Determine where to place
COLLISION INFORMATION
Fig. 16 Door Skin
NOTE: Drain holes must remain clear of
obstructions from adhesives and sealers.
1 ­ DOOR SKIN (OUTER)
2 ­ DOOR SHELL (INNER)
A ­ STRUCTURAL ADHESIVE
B ­ SEAM SEALER
C ­ HEM FLANGE CUT LINE (BOTTOM EDGE SHOWN,
SURROUNDING EDGES TYPICAL)
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