Body Assembly - Saab SONETT III Service Manual

BODY ASSEMBLY
Chassis and body
Body frame
The body fram e can be repaired in accordance with the
directions given in the Service Manual for the SAAB V4.
The special tools recommended there can also be used,
except for the aligning tool No. 784007 which is unsuit-
able "n ,-.^" , .nt of the sh"rter whee!base "n the Sonett !I!.
Body shell
General
The body shell can be repaired either by replacement of
complete parts or by mending the damaged piece, de-
pend ing on the extent of the damage.
When mending local damage, the damaged piece should
be ground away. It is best if both sides can be ground as
per alternative A, but if this proves difficult it will suffice
to grind one side only as per alternative B. In an emergency,
damage can be mended as indicated in Fig. C, where a
reinforcement consisting of fiberglass matting and plastic
has been applied to the rear side. Small holes or pores can
be drilled out and then filled with plastic putty. See Fig. D.
Large holes right through the body shell can be repaired
by securing a mould of rubber, etc., to which release agent
has been applied to the outside of the panel and then
applying plastic and fiberglass cloth to the inside.
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TYPICAL BODY SHELL REPAIRS
S 1212
Body shell repair procedure
Materiels:
Fiberglass matting (type 300 g)
1" brush
Sandpaper (coarse)
Sandpaper (fine)
Acetone
Trichloroethylene
Plastic of good quai ity, e.g. Soredur H43 containing an
accelerator.
Catalyser
Plastic-padd ing
1. Apply masking tape around the damaged area (to
avoid scratches on undamaged parts).
2.
Scrape off all loose particles from the damaged area
with a knife.
3. Roughen up the surface with coarse sandpaper.
4. Degrease the damaged surface with trichloroethylene.
5.
Make sure that the surfaces are properly aligned.
6. Cut out a suitably sized piece of fiberglass matting.
7. Apply catalyser to the plastic. The correct mixing
is usable for 15-20 minutes at room temperature.
8. Coat the damaged area with the plastic rnixture and
then insert the first layer of fiberglass matting. Repeat
this procedure until the damaged part has been com-
pletely filled out. NOTE! Make sure that the fiber-
glass matting is thoroughly drenched with plastic
and that no air bubbles are built in (stipple).
9. Cure for about an hour at 20°C. Examine. After
curing, the surface must be cold and hard.
10. Grind with coarse sandpaper or, in the case of large
irregularities, with a file.
11. F ill any pores and cavities with putty, using either
steel plastic or Plastic-padding.
12.
Smoothen after curing with fine sandpaper.
13. Clean the brush and any tools used immediately in
acetone.
14. Water-grind and coat with enamel.
810-1
SAAB June 1970