Fiat 500 Collision Awareness Manual page 38

38 COLLISION INFORMATION
9. With the aid of an assistant, dry fit the panel. Apply clamps to hold panel in place, making note of locations. Install
screws where accessibility prohibits the use of clamps. This will aid in proper alignment during installation.
10. Without a mixing tip installed, 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: Using scrap metal and adhesive, make test coupon samples and perform peel test to ensure your STRSW
equipment is ready to apply welds as required. The Weld/Weld Bonding section will provide further information
on peel testing and equipment set­up, (Refer to Collision Information ­ Standard Procedure).
NOTE: Refer to the structural adhesives manufacturer for information on work, handling and curing times.
Installation:
12. Install backer panels, refer to Backer Panel Joint
13. Apply 10 ­ 13mm. (3/8 ­ 1/2in.) bead of structural adhesive to the area where the two panels are to be bonded and
weld bonded. Do not apply to areas that will only be STRSW or GMAW welded.
14. Smooth the adhesive with a body filler spreader or equivalent, to cover all bare metal surfaces. Apply a second bead
of adhesive to ensure proper adhesive thickness.
15. With the aid of an assistant place the panel to the vehicle. If the panel needs to be adjusted, slide the panel.
NOTE: Adjustments must be made by sliding, not lifting the panel(s). Lifting will cause air bubbles and weaken
the bond.
16. Install clamps and screws to locations determined during the dry fit process
17. Remove all squeeze out of adhesive, prior to curing.
NOTE: Structural adhesive manufacturers will vary on time allowed for completion of STRSW in weld bond
zones. Check and follow adhesive manufacturer recommendations.
18. Apply STRSW to weld bond area immediately.
19. Once fully cured, remove clamps and screws. When fully cured, expect adhesive to remain a little tacky, as this is
a normal characteristic of the adhesive.
20. Complete STRSW and / or GMAW (plug / puddle ) welds.
21. Finish / Dress the welds as necessary. If screws were necessary bevel the screw holes. Prepare the joint and screw
holes by grinding the area with 50 grit grinding disc. Get in seams as best as possible without thinning the metal.
22. 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.
23. Apply fiber­reinforced waterproof body filler to screw holes and joint. Complete the repair using conventional body
filler, and block sanding.
24. Apply an epoxy or anti­corrosion primer. When cured, lightly scuff and then apply seam sealer as necessary.
25. Prime and paint per paint manufacturer recommendations.
26. Apply inner panel corrosion inhibiting materials (Mopar Cavity Wax part #68042970AA, or equivalent).
Metal Fatigue/Stress Crack
Overview: On rare occasions you may encounter metal fatigue, also referred to as stress cracks. This will appear as a
crack starting at an edge and trailing away. Follow these steps for a proper repair:
1. Locate the trailing end of the crack and drill a 3mm. (1/8in.) hole at the very point at which it stops. This is referred
to as "Stop Drilling".
2. Remove all contaminants and coatings including primer, paint and anti­corrosion, from the repair area. Surface
should be clean and shiny (if pewter in color then anti­corrosion has not been removed).
3. Stitch weld the seam/crack closed using GMAW. Follow welding guidelines as found in Weld/Weld Bonding, (Refer
to Collision Information ­ Standard Procedure).
4. Dress the welds as necessary. Careful not to thin the base metal.
5. Depending on the location and visibility of the repair surface refinishing will vary from body filler, finishing and paint­
ing to simply applying an epoxy or anticorrosion primer and rubberized undercoating, Mopar part #05093417AA or
equivalent.
6. Apply inner panel corrosion inhibiting materials (Mopar Cavity Wax part #68042970AA , or equivalent).
2012 FF