Hardtop Enclosure Broken Section Repair; Hardtop Enclosure Fracture Repair - Jeep 1979 CJ-5 Technical & Service Manual

3P-4 HEADLINING—HARDTOP ENCLOSURE—EXTERIOR DECALS AND OVERLAYS
Fig. 3P-2 Applying Plastic Body Filler with Spreader
Broken Section Repair
(1) Use a grinder to remove paint from both sides,
and to outline damaged area.
(a) Use a grade 24 disc for initial grinding.
(b) Follow up with a grade 50 disc to prevent
coarse scratches from showing up in final finish.
(2) Bevel edges of break on both sides, using a
rotary file as shown in figure 3P-3.
Fig. 3P-3 Beveling Edges of Broken Piece with Rotary File
NOTE; Edges should be beveled on the inside and out-
side on the enclosure to ensure sufficient surface area
for bonding.
(3) Clamp broken piece into place leaving a 1/16-
inch gap along break line.
(4) Mix Structural Adhesive, according to manufac-
turer's instructions, apply liberally to break as shown in
figure 3P-4.
Fig. 3P-4 Applying Structural Adhesive to Broken Piece and Enclosure
(5) Use an air file or hand file board for shaping of
hardened Structural Adhesive.
(a) For initial shaping, use a grade 24 paper.
(b) For shaping and sanding contours in Struc-
tural Adhesive, use a grade 36 or 40 paper.
(c) For finish sanding, use a grade 80 paper.
(6) Apply sealer and color coat (refer to Paint Re-
pair Procedure).
Fracture Repair
(1) Use a grinder to remove paint from both sides,
and to outline damaged area.
(2) Stop-drill crack(s) using 1/8-inch drill bit as
shown in figure 3P-5.
(3) Bevel edges of crack(s) on both sides, using a
rotary file.
NOTE: Edges should be beveled on the inside and out-
side of the enclosure to ensure sufficient surface area for
good bonding.
(4) Cut along length of crack(s) using hacksaw blade
as shown in figure 3P-6.