Chrysler 2004 Concorde Service Manual page 1377

LH
BODY (Continued)
Fig. 4 BEVELING ANGLE - 20 DEGREE
• When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
Fig. 5 FIBERGLASS TAPE
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from the
panel to achieve a successful repair. All spider web cracks
leading away from a damaged area must be stopped or
removed. To stop a running crack in a panel, drill a 6
mm (0.250 in.) hole at the end of the crack farthest away
from the damage. If spider web cracks can not be
stopped, the panel would require replacement. The sur-
faces around the damaged area should be stripped of
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
paint and freed from wax and oil. Scuff surfaces around
repair area with 360 grit wet/dry sandpaper, or equiva-
lent, to assure adhesion of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have access
to the back of the panel to install a patch. Bevel edges
of cutout at 20 degrees to expose a larger bonding area
on the outer side. This will allow for an increased rein-
forcement areas.
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
BODY 23 - 7