Dodge Viper SRT-10 (ZB). Manual - part 229

(1) Cover waxed paper or plastic with adhesive

backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 8).

(2) Tape waxed paper or plastic sheet with mesh to

a surface that has a compatible contour to the repair
area.

(3) Apply a liberal coat of adhesive over the rein-

forcement mesh (Fig. 8). If necessary apply a second
or third coat of adhesive and mesh after first coat
has cured. The thickness of the patch should be the
same as the repair area.

(4) After patch has cured, peel waxed paper or

plastic from the back of the patch.

(5) If desired, a thin film coat of adhesive can be

applied to the back of the patch to cover mesh for
added strength.

PANEL PATCH INSTALLATION

(1) Make a paper or cardboard pattern the size

and shape of the cutout hole in the panel.

(2) Trim 3 mm (0.125 in.) from edges of pattern so

patch will have a gap between connecting surfaces.

(3) Using the pattern as a guide, cut the patch to

size.

(4) Cut scrap pieces of patch material into 50 mm

(2 in.) squares to use as patch supports to sustain
the patch in the cutout.

(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in

from edge of cutout hole (Fig. 7).

(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)

away from edge of patch across from holes drilled
around cutout.

(7) Drill 3 mm (0.125 in.) holes in the support

squares 13 mm (0.5 in.) from the edge in the center
of one side.

(8) Scuff the backside of the body panel around the

cutout hole with a scuff pad or sandpaper.

(9) Mix enough adhesive to cover one side of all

support squares.

(10) Apply adhesive to cover one side of all support

squares.

(11) Using number 8 sheet metal screws, secure

support squares to back side of body panel with
adhesive sandwiched between the panel and squares
(Fig. 9).

(12) Position patch in cutout against support

squares and adjust patch until the gap is equal along
all sides (Fig. 10).

(13) Drill 3 mm (0.125 in.) holes in the support

squares through the pre-drilled holes in the patch.

(14) Apply a coat of adhesive to the exposed ends

of the support squares (Fig. 11).

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

Fig. 8 FABRICATED PANEL

1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER

Fig. 9 SECURE SUPPORT SQUARES TO BODY PANEL

1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL

23 - 8

BODY

BODY (Continued)

(15) Install screws to hold the patch to support

squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.

(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,

grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.

(18) Apply adhesive backed nylon mesh (dry wall

tape) over gaps around patch (Fig. 14).

(19) Mix enough adhesive to cover the entire patch

area.

(20) Apply adhesive over the mesh around patch,

and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).

Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN

1 - CUTOUT
2 - SUPPORT SQUARES

Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES

1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE

Fig. 12 INSTALL SCREWS

1 - PATCH
2 - GAP

Fig. 13 GRIND SURFACE

1 - PATCH
2 - GAP
3 - DISC GRINDER

Fig. 14 COVER GAPS WITH MESH

1 - GROUND DOWN AREA
2 - PATCH
3 - MESH

BODY

23 - 9

BODY (Continued)

PATCHED PANEL SURFACING

After patch panel is installed, the patch area can

be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.

STANDARD PROCEDURE - HEAT STAKING

(1) Remove trim panel.
(2) Bend or move the trim panel components at

the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.

(3) Heat stake the components.

(a) If the heat staked or component seam loca-

tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt

the

material

securing

the

components

together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.

(b) If the heat staked material is broken or miss-

ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the

repair.

(5) Install trim panel.

SPECIFICATIONS

BODY PANELS AND MATERIALS

Most body panels are made of plastic type materi-

als. Different processes are used to create and shape
the panels. Flexible panels are produced from the
rim process.

All panels are fastened with adhesive, rivets, bolts,

and screws or a combination of these fasteners.

Service repair is enhanced as all exterior panels

can be easily removed.

• (RIM) Reaction Injection Molding

• (SMC) Sheet Molded Compound

• (TPO) Thermo Plastic Olefin

• (AL) Aluminum

• RIM (Reaction Injection Molding) – This process

has produced highly flexible plastic panels through-
out the industry, as example is the bumper fascias.

• SMC (Sheet Molded Compound) – SMC is con-

structed using short fiberglass strands usually less
than 5.08 cm (2 inches) long. Sheet stock of glass
impregnated resin matting is placed into the mold
and pressed under heat to flow material throughout
the mold. Tooling is shear edge designed to mold to
net (i.e. no trimming at periphery required).

• For repair procedures (Refer to 23 - BODY -

STANDARD

PROCEDURE

PLASTIC

BODY

PANEL REPAIR).

BODY LUBRICATION

LUBRICATION REQUIREMENTS

Body

mechanisms

and

linkages

should

inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.

Prior to the application of any lubricant, the parts

concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.

LUBRICANT APPLICATION

DOOR LOCK CYLINDERS

(1) Apply a small amount of lubricant directly into

the lock cylinder.

(2) Apply a small amount of lubricant to the key.

Fig. 15 COVER MESH WITH ADHESIVE

1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER

23 - 10

BODY

BODY (Continued)

(3) Insert key into lock cylinder and cycle the

mechanism from the locked to the unlocked position.

NOTE: Do not add more lubricant.

(4) Cycle the lock cylinder mechanism several

times to allow the lubricant to flow throughout the
cylinder.

(5) Wipe all lubricant from exterior of lock cylinder

and key.

ALL OTHER BODY MECHANISMS

(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and

sliding contact areas of component.

LUBRICANT USAGE - BODY

Component

Fluid, Lubricant, or Genuine Part

Hinges:

Mopar

Spray White Lube

Door, Trunk & Hood Springs and Links

Latches:

Mopar

Multi-Purpose Lube NLGI Grade 2

Door, Hood & Trunk

Door Hinge Check Spring

Lubriplate MO-Lith No.2 Grease or Petrocan Multi-flex
Moly EP-2 Grease or equivalent

Seat Regulator & Track

Mopar

Multi-Purpose Lube NLGI Grade 2

Window System Components

Mopar

Spray White Lube

Lock Cylinders

Mopar

Spray White Lube

Parking Brake Mechanism

Mopar

Spray White Lube

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

Description

N·m

Ft. Lbs.

In. Lbs.

Convertible top center/3 bow bolts

—

Convertible top center/4 bow bolts

—

Convertible top cloth support panel screws

—

Convertible top header assembly balance link shoulder bolts

—

Convertible top header assembly rear rail bolts

—

Convertible top latch screws

—

Convertible top lower side arm linkage bolts

—

Convertible top lower side arm linkage support bracket bolts

—

Convertible top seal compression panel screws

—

Convertible top tack strip nuts

—

Decklid hinge bolts

—

Decklid latch bolts

—

Decklid latch striker bolts

—

Decklid lock cylinder nut

—

Door glass screws

—

Door hinge bolts

—

Door latch screws

—

Door outside handle bolts

—

BODY

23 - 11

BODY (Continued)

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