Bodywork Repairs - Filling And Re-Spraying; Plastic Components; Major Body Damage - Repair; Bonnet - Removal And Refitting - PEUGEOT 205 Manual

Aluminium tape should be used for small or
very narrow holes. Pull a piece off the roll and
trim it to the approximate size and shape
required, then pull off the backing paper (if
used) and stick the tape over the hole; it can
be overlapped if the thickness of one piece is
insufficient. Burnish down the edges of the
tape with the handle of a screwdriver or
similar, to ensure that the tape is securely
attached to the metal underneath.
Bodywork repairs - filling and
re-spraying
Before using this Section, see the Sections
on dent, deep scratch, rust holes and gash
repairs.
Many types of bodyfiller are available, but
generally speaking those proprietary kits
which contain a tin of filler paste and a tube of
resin hardener are best for this type of repair;
some can be used directly from the tube. A
wide, flexible plastic or nylon applicator will be
found invaluable for imparting a smooth and
well contoured finish to the surface of the filler.
Mix up a little filler on a clean piece of card
or board - measure the hardener carefully
(follow the maker's instructions on the pack)
otherwise the filler will set too rapidly or too
slowly. Using the applicator, apply the filler
paste to the prepared area; draw the
applicator across the surface of the filler to
achieve the correct contour and to level the
filler surface. As soon as a contour that
approximates to the correct one is achieved,
stop working the paste - if you carry on too
long the paste will become sticky and begin to
"pick up" on the applicator. Continue to add
thin layers of filler paste at twenty-minute
intervals until the level of the filler is just proud
of the surrounding bodywork.
Once the filler has hardened, excess can be
removed using a metal plane or file. From then
on, progressively finer grades of abrasive
paper should be used, starting with a 40
grade production paper and finishing with 400
grade wet-and-dry paper. Always wrap the
abrasive paper around a flat rubber, cork, or
wooden block - otherwise the surface of the
filler will not be completely flat. During the
smoothing of the filler surface the wet-and-dry
paper should be periodically rinsed in water.
This will ensure that a very smooth finish is
imparted to the filler at the final stage.
At this stage the "dent" should be
surrounded by a ring of bare metal, which in
turn should be encircled by the finely
"feathered" edge of the good paintwork.
Rinse the repair area with clean water, until all
of the dust produced by the rubbing-down
operation has gone.
Spray the whole repair area with a light coat
of primer - this will show up any imperfections
in the surface of the filler. Repair these
imperfections with fresh filler paste or
bodystopper, and once more smooth the
surface with abrasive paper. If bodystopper is
used, it can be mixed with cellulose thinners to
form a really thin paste which is ideal for filling
small holes. Repeat this spray and repair
procedure until you are satisfied that the
surface of the filler, and the feathered edge of
the paintwork are perfect. Clean the repair
area with clean water and allow to dry fully.
The repair area is now ready for final
spraying. Paint spraying must be carried out
in a warm, dry, windless and dust free
atmosphere. This condition can be created
artificially if you have access to a large indoor
working area, but if you are forced to work in
the open, you will have to pick your day very
carefully. If you are working indoors, dousing
the floor in the work area with water will help
to settle the dust which would otherwise be in
the atmosphere. If the repair area is confined
to one body panel, mask off the surrounding
panels; this will help to minimise the effects of
a slight mis-match in paint colours. Bodywork
fittings (eg chrome strips, door handles etc)
will also need to be masked off. Use genuine
masking tape and several thicknesses of
newspaper for the masking operations.
Before commencing to spray, agitate the
aerosol can thoroughly, then spray a test area
(an old tin, or similar) until the technique is
mastered. Cover the repair area with a thick
coat of primer; the thickness should be built
up using several thin layers of paint rather
than one thick one. Using 400 grade wet-and-
dry paper, rub down the surface of the primer
until it is really smooth. While doing this, the
work area should be thoroughly doused with
water, and the wet-and-dry paper periodically
rinsed in water. Allow to dry before spraying
on more paint.
Spray on the top coat, again building up the
thickness by using several thin layers of paint.
Start spraying in the centre of the repair area
and then, with a single side-to-side motion,
work outwards until the whole repair area and
about 50 mm of the surrounding original
paintwork is covered. Remove all masking
material 10 to 15 minutes after spraying on
the final coat of paint.
Allow the new paint at least two weeks to
harden, then, using a paintwork renovator or a
very fine cutting paste, blend the edges of the
paint into the existing paintwork. Finally, apply
wax polish.

Plastic components

With the use of more and more plastic body
components by the vehicle manufacturers (eg
bumpers, spoilers, and in some cases major
body panels), rectification of more serious
damage to such items has become a matter
of either entrusting repair work to a specialist
in this field, or renewing
components. Repair of such damage by the
DIY owner is not really feasible owing to the
cost of the equipment and materials required
for effecting such repairs. The basic technique
involves making a groove along the line of the
crack in the plastic using a rotary burr in a
power drill. The damaged part is then welded
back together by using a hot air gun to heat
up and fuse a plastic filler rod into the groove.
Bodywork and fittings 11•3
Any excess plastic is then removed and the
area rubbed down to a smooth finish. It is
important that a filler rod of the correct plastic
is used, as body components can be made of
a variety of different types (eg polycarbonate,
ABS, polypropylene).
Damage of a less serious nature (abrasions,
minor cracks etc) can be repaired by the DIY
owner using a two-part epoxy filler repair
material. Once mixed in equal proportions,
this is used in similar fashion to the bodywork
filler used on metal panels. The filler is usually
cured in twenty to thirty minutes, ready for
sanding and painting.
If the owner is renewing a complete
component himself, or if he has repaired it
with epoxy filler, he will be left with the
problem of finding a suitable paint for finishing
which is compatible with the type of plastic
used. At one time the use of a universal paint
was not possible owing to the complex range
of plastics encountered in body component
applications. Standard paints, generally
speaking, will not bond to plastic or rubber
satisfactorily. However, it is now possible to
obtain a plastic body parts finishing kit which
consists of a pre-primer treatment, a primer
and coloured top coat. Full instructions are
normally supplied with a kit, but basically the
method of use is to first apply the pre-primer
to the component concerned and allow it to
dry for up to 30 minutes. Then the primer is
applied and left to dry for about an hour
before finally applying the special coloured
top coat. The result is a correctly coloured
component where the paint will flex with the
plastic or rubber, a property that standard
paint does not normally possess.

5 Major body damage - repair

The construction of the body is such that
great care must be taken when making cuts,
or when renewing major members, to
preserve the basic safety characteristics of
the structure. In addition, the heating of
certain areas is not advisable.
In view of the specialised knowledge
necessary for this work, and the alignment jigs
and special tools frequently required, the
owner is advised to consult a specialist body
repairer or Peugeot dealer.

6 Bonnet - removal and refitting

complete
Removal
1 Open the bonnet and support with the stay.
2 Using a pencil, mark the position of the
hinges on the bonnet (see illustration).
3 Unbolt the braided lead and disconnect the
windscreen washer tubing (see illustration).
5
2
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