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1A- 1 0 BODY
INSPECTION
Inspect crossmembers for damage .
Any
damaged rib will have to be straightened,
replaced, or have shim material fastened to
the rib so proper support will be provided for
the panel .
PANEL INSULATION
New body panels must be insulated to insure
temperature control and good performance of
heating and air conditioning systems. Insulate
with rigid urethane foam (available in aerosol
cans) or 1-inch, 1 1/2 lb . density fiberglass
insulation sheets, cut to fit.
Both types of
insulation are available locally. Do not cover
areas
which
must
remain
accessible
for
servicing,
such
as structural
flanges and
interior component
mounting sufaces .
If
urethane foam is used, take care not to spray
adhesive bonding surfaces.
Figure i 1-Panel Removal With Air Chisel-Step 4
With the largest part of the panel out of the
way it will now be easier to remove the
remainder of the panel (which is secured to the
crossmember with adhesive) without damaging
the crossmember .
4. Using a Flat End Scraper Bit (J-26805-2),
operate the air chisel along the rib line and
underneath
the panel piece to break the
adhesive bond between the panel and the rib.
Note that figure 11 shows panel "remains"
from two body side panels (panel A & panel B)
being removed from the structural support.
This would be necessary only if both panels
were damaged .
If only one panel needs
replacement, only one panel is removed from
the rib, using the visible seam between panels
as a guide. (Refer to figure 11.)
Follow the same 2-part cutting method
along the roof seams and any other structural
supports that border damaged panels.
Use
care not to damage structural components
behind adjacent panels. All small pieces which
have broken free must be removed.
ADHESIVE REMOVAL
Before prefitting or any further structural
work on the vehicle, the old cured adhesive
must be removed from ribs and body structural
supports .
A suggested method would be to
grind off the adhesive with an extra coarse
disc on an air driven grinding wheel.
An air
chisel with Flat End Scraper Bit (J-26805-2)
may also be used.
PREFITTING
A replacement panel should be prefitted for
proper fixturing after panel has been insulated
and ribs have been thoroughly cleaned of
adhesive . This should be done before the ribs
have been solvent wiped or primed, in order to
prevent later contamination from dirt, grease,
fingerprints, etc . i n the glue line areas.
Next, with the panel held in place, use
existing holes or drill holes through the panel
and rib (at each corner and along the beltline
or roof line) for using pop-rivets .
After
drilling first hole, make sure panel is flat
before drilling second hole .
The panel should
not be bowed between holes.
ABRASION
Aluminum panels and body frame parts
should be disc sanded to bare metal in areas
which will be bonded. Fiberglass* may also be
scuffed on bond line . Finished surface will be
rough to the touch .
*Glass fiber reinforced panels, commonly
called fiberglass . Not the same as fiberglass
insulation referred to earlier.
SOLVENT
BEFORE WORKING WITH SOLVENT, BE
SURE
TO
READ
MANUFACTURER'S
INSTRUCTIONS AND TAKE ALL NECESSARY
SAFETY PRECAUTIONS .
Wipe
bond
surfaces
on
fiberglass
and
aluminum panels
and
on
body
structural
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