SYNTHETIC-RESIN PARTS REPAIR PROCEDURES



Resin fender repair steps





Repair judgment



Applicable repair range



  • In case of a hole, the damaged area is reshaped to be a circle or ellipse for easier filling of the repair agent. The diameter or major diameter should be 50 mm or shorter.

  • In case of a crack or tear, if the both ends of the crack or tear are not separated from the body, the length of the area should be 200 mm or shorter. If one end of the crack or tear reaches to the fender end, the length of the area should be 200 mm or shorter, and also the size should be one-half or smaller of the fender width of that area.

  • In case of a scratch, the area should be 200 x 120 mm or smaller.

Fender removal and cleaning



  • The damage of holes, cracks, and tears requires a repair work from the rear surface. Remove the fender to clean the whole surface, degrease the front and rear surfaces of the repair area using Silicone Off, and then repair by holding the fender to avoid twisting.

Repair work points



1. Cleaning



Degrease the rear surface repair area using Silicone Off, and remove the wax and oil completely.

2. Reshaping of the rear surface repair area



note The grind surface area should be larger than the resin putty application area.
Remove burrs on the rear surface repair area, and grind with a sandpaper #60 to #80 as a surface preparation for painting. When using a sander #80, grind at a low speed of 1500 r/min because the grinding heat will melt the resin.
Brand name: 3M ATD Roloc sanding Disk #80

3. Cleaning and degreasing



Degrease the rear surface repair area using Silicone Off, and clean the surface completely.

4. Application of the adhesive



To achieve secure contact, apply the adhesive to the rear surface reinforcement area by squeezing.
Brand name: 3M ATD 4040 DURAMIX

5. Fixing of the glass cloth (Backing)



Fix the glass tape to the rear surface repair part.
Tape: Glass cloth tape
Brand name: 3M ATD 6400 Glass Cloth Tape

6. Application of the adhesive



Apply the adhesive to cover the fixing glass cloth and its surrounding area. Then smooth it using a spatula, and dry.

7. Adjustment of the front surface base



Remove burrs on the front surface area, and grind as a surface preparation for painting. The grind surface area should be larger than the forming material (such as resin putty) application area. Form the forming material (such as resin putty) application area in a V-shape as much as possible to prevent the expansion of application area and the exposure of application trace. Remove the grinding residue, and degrease.
Brand name: 3M ATD Roloc sanding Disk #80

8. Filling (Putty application)




caution When mixing the liquid, make sure that the air is not mixed in.
1.Degrease the repair area using Silicone Off, and remove the wax and oil completely.
2.In case of a scrape, apply putty to the repair area.
Brand name: Refer to the table below.
The drying time is indicated in the table below.
Brand name
Curing time
Temperature
3M ATD 4058 DURAMIX
8 - 10 minutes
25°C
3M ATD 8120 Plastic Patty
30 minutes
60°C
ROCK PAINT 057-970 ROCK Bumper Patty
10 minutes
60°C

9. Surface grinding



After drying, grind with a sandpaper #120.
note Grinding available time: 8 to 10 minutes after application (23°C)

10. Surface preparation for primer-surfacer



Grind with a sandpaper #180 to #240. Grind the primer-surfacer application area as a surface preparation for painting. In addition, remove the grind mark.

11. Cleaning and degreasing



Degrease the surface using Silicone Off, and clean it completely.

12. Masking


To avoid splashing of primer-surfacer during the coating, apply masking.
Masking: MASKING paper tape
Brand name: 3M ATD Performance Masking Tape 233

13. Primer-surfacer coating



caution
  • If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack.
  • For colour separation, use the masking tape.
While taking a flash off time, apply 1 to 3 times of double coating, using a spray gun.
Brand name: Refer to the table below.
The drying time is indicated in the table below.
Name
Curing time
Temperature
ROCK PAINT HB Primer Surfacer F-II
40 minutes
60°C

14. Primer-surfacer grinding



1.Grind the base surface slightly with a sandpaper #240 to #320.

2.Apply the putty to cover pinholes, grind marks, and slight distortion. Do not apply an excessive amount at a time. Repeat application of small amount, taking a drying time.

3.Grind with a sandpaper #240 to #320.

caution If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack.
4.While taking a flash off time, apply 1 to 3 times of double coating, using a spray gun.

5.Dry sand with a sandpaper #240 to #300 or finer. Then, as a surface preparation for painting, grind lightly so as not to expose the base surface. Finally, use a sandpaper #600 (#800 for dark colour coating) or finer to remove grind marks.

15. Top coating



caution If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack.
While taking a flash off time, apply 1 to 3 times of double coating, using a spray gun.

16. Clear coating (Repair symbol 2M, 2P, and 3P of Body Colour Table)


Apply the clear coat.
The drying time is indicated in the table below.
Curing time
Temperature
60 minutes
60 °C