Ford Focus RS (2011 year). Instruction - part 138

Additional Materials

The manufacturer's instructions must always
be followed when dealing with any materials!
The information given in the following text is data
which is independent of the manufacturer, and it
should only used as an indication.

Adhesive sealants

Adhesive sealants are permanently elastic,
long-lived, can be painted and accept filler.

Application: Sealing of visible and normal seams.

Can be over-painted with 2-component paint,
primer and fillers after having dried throughout.

Contamination can be removed using cleaner and
thinner.

1-component PUR adhesive sealant

Note:

• Hardens using oxygen from the air. For that

reason, it must only be stripped after it has
completely dried through.

2-component MS polymer adhesive sealant

2-component MS polymer adhesive sealant is free
of isocyanate, solvent and silicones and can be
spot-welded.

MS polymer adhesive sealant

Can be over painted with water-based paints.

Suitable for spraying and brushing to obtain a
composition true to the original.

MS polymer adhesive sealant is free of isocyanate,
solvent and silicones and can be spot-welded.

Underbody protection

Underbody protection products are immune to
abrasion, permanently elastic, adhere well and are
suitable for a true to original texture.

Underbody protection based on solvent

Application:

• Underbody protection for visible areas.

Properties:

• Can be over-painted, also with 2-component

paint.

• Can be colored with a proportion of up to 40%

paint.

Note:

• Contamination can be removed using cleaner

and thinner.

Water based underbody protection

Can be over-painted with water based paint.

Can be colored with water based paint.

Contamination can be removed using water.

Water based underbody

protection

Application

Underbody protection

for visible areas

Use

ready to use

Spray viscosity

Suction beaker HVLP

gun 3 - 4 mm

Spray gun

4 - 6 bar

Spray pressure

500 - 1000 µm

Layer thickness

approx. 6 hours at 20°C

Drying

approx. 45 - 60 minutes

at 60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Water based underbody

protection

Application

Isolation primer for

peroxide marks, bloomed
old paintwork and thermo-

plastics.

Use

G468097en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Water based underbody

protection

Application

Thin as necessary with

distilled water

Spray viscosity

HVLP gun 1.9 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

40 - 50 µm

Layer thickness

approx. 2 hours at 20°C

Drying

approx. 30 minutes at

60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Paint additives

Sanding test color

Application

To test sanding results

Use

HVLP 1.7 - 1.9 mm

Spray gun

2.0 bar

Spray pressure

Spray drifted

Layer thickness

Fixer additive

Application

Converts solid top coat

into two layer solid; multi-

color painting

Use

18 - 20 secs at 20°C

Spray viscosity

HVLP 1.2 - 1.3 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

max. 30 µm

Layer thickness

Wet on wet

Coat application

approx. 15 - 30 minutes

Ventilation time

Maintain maximum layer thickness without fail.

Must always next be overpainted with clear lacquer.

Drying accelerator

Application

Accelerates drying with

only minimal reduction in

working life

Use

approx. 5 hours at 20°C

Working life

Drying accelerator

Application

HVLP 1.2 - 1.3 mm

Spray gun

2.0 bar

Spray pressure

50 - 70 µm

Layer thickness

approx. 6 hours at 20°C

Drying

approx. 25 minutes at

60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Cannot be used in all paints, read the
manufacturer's instructions.

Particularly suitable for partial painting.

Elastifier additive in

primer material

Application

Elastifies the complete

paint structure on

plastics.

Use

Up to 25%

Addition

HVLP 1.7 - 1.9 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

50 µm

Layer thickness

approx. 4 hours at 20°C

Drying

approx. 40 minutes at

60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Elastifier additive in top

coat

Application

Elastifies the complete

paint structure on

plastics.

Use

Up to 25%

Addition

HVLP 1.7 - 1.9 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

50 - 60 µm

Layer thickness

G468097en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Elastifier additive in top

coat

Application

approx. 16 hours at 20°C

Drying

approx. 45 minutes at

60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Matting additive in solid

paint

Application

Elastifies the complete

paint structure on

plastics.

Use

Up to 25% in the paint

without hardener and

thinner

Semi-gloss addition

Up to 35% in the paint

without hardener and

thinner

Silk gloss addition

Up to 45% in the paint

without hardener and

thinner

Silk matt addition

HVLP 1.2 - 1.3 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

50 - 70 µm

Layer thickness

approx. 8 hours at 20°C

Drying

approx. 30 minutes at

60°C

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

CAUTION: Do not dry using infrared.

Matting additive in clear

lacquer

Application

Elastifies the complete

paint structure on

plastics.

Use

Matting additive in clear

lacquer

Application

Up to 25% in the paint

without hardener and

thinner

Semi-gloss addition

Up to 35% in the paint

without hardener and

thinner

Silk gloss addition

Up to 45% in the paint

without hardener and

thinner

Silk matt addition

HVLP 1.2 - 1.3 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

50 - 70 µm

Layer thickness

approx. 8 hours at 20°C

Drying

approx. 30 minutes at

60°C

Note:

• When mixing, first put in the matting additive,

then the hardener and thinners.

• Stir immediately after adding the matting

additive.

• Do not store after addition of the matting

additive, storage will change the degree of
gloss.

• Also suitable for use on plastics without addition

of elastifier additive.

Matting paste

Application

Matts, elasticizes and

gives structure to solid

paint and clear lacquer

during painting of

bumpers or hard plastic.

Use

1:1 or 2:1 depending on

manufacturer in solid

paint without hardener or

thinners.

Addition

HVLP 1.2 - 1.3 mm

Spray gun

2.0 - 3.0 bar

Spray pressure

50 - 70 µm

Layer thickness

approx. 6 - 10 hours at

20°C

Drying

approx. 30 minutes at

60°C

G468097en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Matting paste

Application

Short wavelength infrared

approx. 8 minutes

Medium wavelength

infrared approx. 10 - 15

minutes

Note:

• The paint must not be filtered.

Anti-silicone additive

Application

Prevents silicone craters

Use

2% to maximum 5%

Addition

Note:

• Only add away from the paint cabin and

immediately remove contaminated cloths.

• If anti-silicone additive is used in the first coat,

then it must be used in the following coats, and
in at least the same proportions.

Additive materials

Variety of adhesive tapes

For profile, fine and large area masking work.

Properties:

• Withstands heat.

• Withstands water-based paint.

• Accepts paint.

• Easily removed without leaving adhesive

residues.

Masking film.

For masking of large areas on vehicles.

Properties:

• Accepts 2-component and water-based paints.

• Withstands heat.

• Withstands water spray and condensation.

• Withstands solvent.

• Easily cut.

• Environmentally friendly and can be recycled.

Polishing materials.

Polishing means microfine sanding. For this
reason, polishes must only contain abrasives, and
no silicones.

During polishing repair, a good shine is achieved
through the step-by-step use of polishes, starting
with a highly abrasive polish and ending with a
polish having very slight abrasive action.

Polishes are available in graduations from coarse
to fine.

Abrasives

Please refer to the "Tools" chapter

for

information

abrasives.

G468097en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Paint Repairs

General information

There is a great difference between painting in
production and repair painting.

In production, only the bodyshell is painted, it has
no trim, upholstery or assemblies. Because of this,
other paints, tools and processing techniques can
be used.

In contrast to that used in production, paint used
in the workshop must dry at low temperatures.
Plastics and the vehicle electronics must not be
subjected to temperatures greater than 70°C.

The painting process in the case of repair work
consists of two phases:

• Pre-treatment of the surface for corrosion

protection and the smoothing of irregularities.

• Top coat application.

The precondition for a professional paint finish on
a vehicle is the permanently maintained cleanliness
of work spaces, tools and equipment,

Original materials must be worked according to the
manufacturer's instructions, so that no problems
arise in the processing nor during drying.

The room temperature must be 20 - 25°C and the
humidity must be low. Temperatures which are too
low or too high can lead to porosity, poor flow and
boiling. High humidity leads to paint damage such
as tarnishing of the paint film (matt film), adhesion
problems and craters.

Pre-treatment of the surface

Perfect preparation of the subsurface is the
precondition for a brilliant paintwork result. Faults
in the preliminary stages delay completion and
cause unnecessary extra work. The working steps
described here demonstrate how important it is to
follow these instructions step by step.

NOTE: Thorough cleaning of the vehicle and
especially of the area being repaired is particularly
important because of the danger of contamination
of the paint.

Clean the area of the damage

Clean the damaged surface thoroughly, to allow
the extent of the damage to be seen. Use silicone
remover to produce a grease-free surface.

NOTE: The treated surface must be rubbed with
a clean dry cloth before the solvent evaporates,
otherwise there will be no cleaning effect.

Effective de-greasing is important not only before
the application of paint, but also before all sanding
stages, for two reasons:

• During sanding of grease contaminated

surfaces, globules may form with the sanding
dust. Sanding marks will occur and the sanding
medium quickly becomes unuseable.

• Oil and grease are embedded by the action of

the abrasive particles, and are then very difficult
to remove.

Establish the area of damage and the repair
stages. In doing so, establish how much
disassembly work must be undertaken. Perform a
color test at this stage.

Mask off the area of the repair ready for
preparatory work.

Sand out the damage location

G506672en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

When sanding, produce smooth transitions from
the painted area to the bare metal.

Use an eccentric sander and P80 or P120 abrasive
sheets. Finish off sanding with P150 or P180. The
remaining adhering sanding dust must be
completely removed.

Cleaning, de-greasing

Use silicone remover to thoroughly clean the
surface in order to remove grease residues, sweat
from the hands and other contamination.

NOTE: Use a solvent test to establish whether the
old paint can be etched. Apply 2-component
thinners to the damaged area using a clean cloth
and rub lightly for about 1 minute. If the
subsurfaces can be etched away, special
pre-treatment is necessary. See "Tips and Tricks"

Apply primer filler

Before applying stopper, apply primer to the
sanded and bare surface.

Allow the primer to dry and then lightly sand by
hand using P220 - P400 dry.

NOTE: Most stopper can be applied directly to bare
metal. But application of a primer filler provides
better corrosion protection.

NOTE: Avoid sanding through to the bare metal.
Points which are sanded through must be retreated
with primer filler.

Stopper application

Pre-sand the hardened stopper using an eccentric
sander and P80 dry, then final-sand using P120 -
P140 dry. Clean the sanded surface using silicone
remover.

Apply 2-component stopper to the filled surface.
The stopper compound must only be applied thinly.

NOTE: Use of a testing powder is recommended
so that the sanding process can be more easily
checked.

Apply filler

Filler can now be applied to the dried repair area.
Choose the correctly toned filler according to the
manufacturer's instructions.

NOTE: Alternatively, filler with the correct tone can
be mixed with the aid of colour matching cards.

G506672en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Sand the filler.

The working area is expanded by applying new
masking. This makes it possible to even out the
transition from the damage area to the vehicle
paintwork.

NOTE: The primer filler must be carefully sanded.
Faults in the primer filler layer will be visible in the
top coat.

The sanding process consists of two stages.
Coarse sanding levels out the surface of the filler
primer. Fine sanding ensures the necessary
surface structure which allows the top coat to
adhere well and cover sanding marks.

Sand the filler using the eccentric sander and P400
- P500 used dry. Clean the sanded filler finished
surface using silicone remover.

The painted area is matted using a fine matting
sponge, and then thoroughly cleaned.

Surface ready for paint

The surface which has been repaired and then
prepared according to the manufacturer's
instructions is now ready for basic paint application.

Top coat application

It is important for a good paint result that the
recommended process data is adhered to, i.e.

mixture proportions, layer thickness, viscosity,
drying time etc.

First of all the work area is carefully masked ready
for paint application. The correct adhesive materials
and techniques must be used so that no hard
transitions and edges are created during painting.

NOTE: The chapter "Tips and Tricks" gives
in-depth information on masking work.

Thoroughly check the surface once more and
rub-off with a dust-bonding cloth.

NOTE: Once more check the paint material and
that the spray gun is correctly adjusted before
applying the paint.

Paint application

The base paint is applied in two or three steps.
First of all only the repair area is painted with the
first paint application.

Flash off

Allow the paint application to flash off until the
surface has a matt appearance. So that the
transition to the original paint is optimally created,
the next paint application is applied to a wider area.

After the base paint has dried for the specified time,
the clear lacquer is applied. Next the transitions to
the original paintwork are treated with fade-out

G506672en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

remover. This removes the spray mist and forms
an ideal paint surface.

Repair stages for repair painting

The required time and material data is divided into
four painting levels for calculations concerning
repair painting. Proceed according to these
divisions for every calculation.

Level 1 - Painting of new components

On new components, all inner surfaces, seams
and edges which will no longer be seen after
assembly must be primed and pre-painted.

NOTE: The cathodic dip primer must not be sanded
away. Cleaning with silicone remover or light
sanding of the primer is all that is required.

Job steps:

• Wash off, prime and pre-paint inner surfaces,

seams and edges which cannot be reached at
all or only partly after the component is installed.

• Sand new component with P280 - P320 or a

fine sanding pad.

• Clean subsurface with silicone remover.

• Carry out masking work (when painting an

installed component).

• Apply one spray run of filler, dry.

• Sand the filler. P1200 wet or P500 dry.

• Clean filler application with silicone remover.

Then the prepared surface can be painted with
solid or 2-component paint.

If the new part has mild transport damage, this
must be rectified beforehand.

To do so, add the following steps:

• Grind out the scratch.

• Finely sand the surrounding surfaces.

• Use a steel cleaning agent to thoroughly clean

and then rub dry.

• Apply corrosion protection primer to the bare

areas.

Level II - Top surface painting (color tone matching)

Complete bodywork surfaces which are to be
painted without the need to apply stopper belong
to this group. In addition, surfaces with faults in the
top coat surface which cannot be removed by
polishing.

The following faults are included:

• Loss of gloss.

• Sanding scores.

• Heavy paint runs.

• Large dust and dirt inclusions.

The scope of the work is as follows:

• Sand the surface.

• Sand out paint damage and faults.

• Treatment of small areas which have been

sanded through.

• Masking work (when painting an installed

component).

• Apply top coat according to the painting process

(one or several coat process).

• Dry the top coat and perform finishing work.

Level III - Repair painting with stopper applied to up
to 50% of the surface.

If in addition to painting, work with stopper
application must be performed, then the repair
levels III or IV must be used.

In repair level III, apart from painting the complete
bodywork surface, partial stopper work is carried
out on up to 50% of the surface to be painted. The
necessary primer and filler work are also included.

The following damage must be rectified in this level:

• Slight panel unevenness.

• Damage due to corrosion.

• Dented body surfaces.

• Weld locations.

• Deep scores or scratches.

The scope of the work is as follows:

• Fine sand pre-treated bodywork surfaces (e.g.

lead-loaded areas).

• Sand out existing damage.

• Perform all necessary masking operations on

the vehicle.

• Apply primer.

• Partial stopper application on up to 50% of the

surface to be painted (two to a maximum of
three stopper applications).

• Fill the repair area.

• Apply stone chip protection (when present in

production).

• Apply top coat according to the painting process

(one or several coat process).

• Dry the top coat and perform finishing work.

G506672en

501-36-

Paint - General Information

501-36-

DESCRIPTION AND OPERATION

Content .. 136 137 138 139 ..