Ford Falcon. Manual - part 522

 

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Ford Falcon. Manual - part 522

 

 

501-32-3 

Paint Preparation and Application 

501-32-3

DESCRIPTION AND OPERATION (Continued)

at any time. Isocyanates react with water, which

refinishing is to be the in-field equivalent of the factory

destroys their effectiveness. Gas is involved when the finish. Two part urethane finishes are recommended.

isocyanate reacts with water. If a closed container

Two Pack Paints - Surface Preparation

shows signs of internal pressure, cover it completely

with a cloth and remove the lid slowly to prevent

Essential Requirements and General Hints

splashing or violent expulsion of the lid. If using only

1.  Wash door jambs, engine compartment, etc with

portion of the hardener in a can, reseal and use the

high pressure hose before sanding and priming.

balance of the contents within 36 hours, as it will

This will remove all dust and dirt likely to

deteriorate on exposure to air. Store in a cool, dry

contaminate the top coat.

place.

2.  Wash surface thoroughly with a grease and wax

Accidental spillages should be absorbed into dry sand

solvent before sanding and application of primer.

or earth, removed from the work area and covered

Sanding will not remove wax and grease. Instead,

with water for 24 hours. Treat empty hardener

it spreads it from one panel to another, leading to

containers in the same manner. Do not allow

poor adhesion, and cratering if sealed in the

materials of this type to enter drains. Dispose of

primer.

treated waste as directed by the relevant waste

disposal authorities.

3.  Strain lumpy primers and filler before adding

hardener. Lumps will not catalyze and will remain

Application

soft. These soft areas will show after top coating.

Isocyanate paint must only be applied in a spray

4.  Wet sand primers and top coats containing

booth fitted with an effective filtered exhaust system.

isocyanates. Dust particles containing isocyanates

The operator must wear the protective equipment

can be hazardous to health.

prescribed in these guidelines and comply with local

5.  Use solvents sparingly over primers and fillers. It

legislation applicable to the spray painting of motor

can take up to two hours for cleaning solvents to

vehicles.

evaporate. If sealed in with the top coat it can

Additionally, particular care must be paid to other

cause “whirl” marks to appear in the paint film.

people in the vicinity. The work area should be

6.  Mask off vehicle openings, door jambs, engine

isolated from other people during all activities

compartments, wheel arches, etc. This will reduce

associated with the mixing, handling and application

the risk of dust and dirt blowing out during top

of isocyanate paint until all vapour and spray mist, etc.

coat spraying.

has been effectively dissipated.

7.  Never apply two pack primers over unsanded

Whenever unlidding, mixing or the clean-up of liquid

surfaces, especially existing finishes. Adhesion

residues is taking place, the area in use must be well

will be poor. The primer edge will not feather

ventilated by an exhaust system sufficient to capture

properly and will lift or swell when top coated.

all vapour or spray mists generated and conduct them

8.  Never use conventional etch primers under two

away to a safe discharge point. Where the air flow

pack primers. Two pack primers have good

velocity in the work area is below 1 metre per second,

adhesion to all bare metals but not to

at least one hour should be allowed before the

conventional etch primers.

exhaust ventilation is switched off.

9.  Never attempt to use two pack primers or fillers to

Wet sanding is the preferred method. Sanding of

seal down cracked or crazed surfaces or film

isocyanate films should be carried out under the same

thicknesses exceeding 250 microns. Unless

conditions as apply to spraying, as the dust may

stripped, this type of surface will continue to crack

irritate operators susceptible to isocyanate contact.

under any primer and will eventually pull open the

First Aid

new top coat.

10. Never use polyester spray fillers on wet or humid

If affected by inhalation of vapour or spray mist,

days. Polyester spray fillers are very moisture

remove to fresh air. If breathing difficulty persists or

absorbent and will blister easily. They should be

occurs later, consult a doctor and have label

dry sanded and primed as soon as possible after

information available.

application.

In case of eye contact, flush immediately with plenty

11. Never use too coarse a paper on final sand of

of water for 15 minutes; call a doctor. In case of skin

primer before application of top coat. They have

contact, remove contaminated clothing and wash skin

low film build and will not fill coarse scratch

thoroughly with soap and water. Immerse

marks.

contaminated clothing in water for 24 hours and do

not re-use until it has been laundered.

12. Do not exceed these levels of coarseness.

Factory Finish

The vehicle is finished in either baked polyester solid

colour or baked acrylic clear over base coat colour; all

G456450 en

501-32-4 

Paint Preparation and Application 

501-32-4

DESCRIPTION AND OPERATION (Continued)

Base coat ...................800 grit weld

8.  Never attempt to alter colour after hardener has

been added. This will throw out mixing ratios

2K acrylic enamel ......600 grit weld

resulting in poor product performance.

13. Never allow water to dry on panel before

9.  Never wash base coats with solvent before

application of any paint material. When water

application of clear. Base coat will wash off.

evaporates, it leaves behind mineral salts. In wet

weather, these salts absorb moisture and will

10. Never apply heavy wet coats. This can result in

swell under the paint film causing blistering.

possible “solvent boil” and “runs”.

11. Never recoat base coat with itself after two hours,

Mixing

without detail sanding. Adhesion between the two

1.  Use a measuring gauge when adding hardener

layers of base coat will be very poor.

and reducer. Ratios either under or over will lead

12. Never apply more than four full coats of base

to poor product performance.

coat. As there is no hardener in base coat, thick

2.  Replace lids on cans of hardener immediately

film build will remain soft, with the result that the

after use. Hardeners are hydro-scopic (will absorb

clear coat will remain soft and spongy.

moisture from the air), sometimes going “milky”

13. Never apply two pack materials at temperatures

and causing top coats to look “gritty” or “seedy”

below 7 degrees C. Two pack materials cease to

when sprayed.

cure below 7 degrees C, but will recommence as

3.  Strain two pack top coats and sealers through a

the temperature rises, resulting in possible loss of

150 micron filter before application. This will

gloss.

remove any foreign matter that may be in the

14. Never apply two pack materials in excessive

paint, eliminating the need to denib and buff later.

humidity outside a spray booth. This practice

could result in loss of gloss and/or humidity

Application

blistering.

1.  Use correct air pressure (normally 350-420 KPa).

15. Never attempt to spray material which has started

Too low an air pressure will give poor atomization

to “gel”. Pot life has ended. Application properties

and will result in a peely finish. Too high leads to

and product performance will be poor, even if

excessive overspray and dry finishes.

extra reducer is added.

2.  Use the recommended drying speed of hardener

After Spraying

and reducer for different temperatures. This will

give the best application results. Always check the 1.  Never leave a newly painted vehicle in the rain or

product data sheets.

dew for at least:

3.  Give transparent sealer time to “tack off” before

24 hours .........Air Dry

applying top coat. Top coats may split if applied

6 hours ...........After full bake cycle

too soon.

2.  Failure to observe these times may result in loss

4.  Apply clear coat over base coat as soon as

of gloss and/or “humidity blistering” and water

possible as adhesion between base and clear

spotting.

may be reduced, if delay is excessive, i.e. more

3.  Never let respray stand for more than 5 minutes

than about 12-15 minutes. (Refer to paint supplies

before baking. Surface will “skin” trapping in

literature for optional timing between base coat

solvent. Heat will not reflow the surface but will

and clear coat).

force the solvent out too quickly, resulting in

5.  Wear the correct safety equipment when spraying

possible “solvent boil”.

materials containing isocyanates. Contact with

4.  Never bake for more than 40 minutes or at

isocyanates may result in respiratory problems.

temperatures above 70 degrees C as this will

6.  Never apply transparent sealer over fresh acrylic

damage plastic parts and fillers and cause failure

lacquer top coats or lacquer primers, a minimum

of electronic components.

of one month is required to release all solvents

5.  Do not use polishes containing wax or silicone for

from these materials. Sealed in solvent, prevented

at least:

from evaporating by the sealer will result in sink

back, possible blistering and lack of adhesion.

1 month .........After Air Dry

7.  Never allow transparent sealer to dry longer than

1 week ...........After full bake cycle

two hours before top coating. Excessive drying

6.  While solvent is still evaporating from a paint film,

can cause “fry”; first recoat with sealer then top

the surface is “open”, risking penetration from

coat.

silicone, waxes, etc., resulting in possible loss of

gloss.

G456450 en

501-32-5 

Paint Preparation and Application 

501-32-5

DESCRIPTION AND OPERATION (Continued)

6.  Allow 15-20 seconds contact time then dry off with

Painting Plastic Bumper Bars

a separate clean cloth.

Recommended Materials

7.  Repeat the process three times.

1.  The following procedures have been performed

NOTE: Do not allow Bodykleen or D846 to dry on

using the PPG line of products referred to below.

surface.

Other commercial equivalents may be

satisfactorily substituted.

Colour Finishing of Replacement Bumper

bars

2.  Front and rear bars installed on falcon are made

from high impact strength Polypropylene/EPDM

1.  Replacement bumper bars are supplied with front

plastic.

cover unpainted and require refinishing from

3.  It is essential that approved methods, materials,

primer to topcoat before installation.

paints, etc. or the equivalent of these be

The valance should be cleaned by wiping with

employed when paint repair operations are

a clean rag soaked in D846 Degreasing Agent

performed and when preparing new parts for

for Plastics allowing contact with the surface

installation.

for 10-15 seconds then wiping dry with a new

The approved products are:

dry clean cloth.

PPG - GRS BODYKLEEN

- 920 - 35609

Repeat procedure.

PPG - GRS DEGRESING AGENT

- 499 - D0846

Apply a double coat of D820 Plastic adhesion

FOR PLASTICS

promoting primer. Allow 15-20 minutes drying

time before top coating.

PPG - GRS PLASTIC ADHESION

- 499 - D8020

PROMOTER

NOTE: Correct cleaning is important prior to painting

plastic parts. Observe safety procedures and obtain

PPG - GRS PLASTICISER

- 499 - D0814

the required respirator as these products contain

FLEXIBLE ADDITIVE FOR TWO

isocyanate.

COMPONENT PRODUCTS
PPG - GRS B.C. BASECOAT

- 452 LINES

Solid Colour

PPG - GRS MEDIUM THINNER

- 920 - D0871

1.  To the matched colour add D814 Plasticiser then

PPG - GRS 2K CLEARCOAT

- 455 - D0800

hardener and reducer in the following ratios:

PPG - GRS D.G 2K ACRYLIC

- 402 - LINE

ENAMEL

402 line colour

3 parts by

PPG - GRS 2K MEDIUM

- 980 - D0841

volume

HARDENER

D814 Plasticiser

499 - D0814 1 parts by

PPG - GRS MEDIUM THINNER

- 920 - D0871

volume

PPG - GRS D839 PRIMA PRIMER

- 467 - D0839

D841 medium

980 - D0841 2 parts by

PPG - MIRLON ABRASIVE PADS.

- 947 - 48673

hardener

volume

PPG - A652 IVIPLAST FILLER

- 468 - A652

Stir thoroughly and strain. Put on the air

*PPG and GRS are registered trade marks of PPG

supplied respirator.

industries Australia Pty. Ltd.

Using a 1.3-1.6 fluid nozzle on a conventional

4.  Correct cleaning is important prior to painting

or H.V.L.P spray gun apply one medium wet

plastic parts. It will be necessary to remove dirt,

coat.

grease, mould release agents (if part is new) and

Allow a 3-5 minute flash off and apply 1 full

other contaminants prior to painting.

wet coat. If low baking, this can be done

immediately at 60

° for 30 minutes. If air drying

Preparation

allow 8 hours to dry. (Correct film thickness is

1.  Remove any waterborne contaminants with PPG

40-50 microns).

Bodykleen 920-35609. Mix 1 part Bodykleen to 4

parts warm water.

Base coat Metallic/Pearl Colour and Clearcoat

2.  Apply mixed Bodykleen to plastic part with a

1.  Thin the matched Basecoat colour with 100%

non-metallic pad such as PPG Grey Mirlon pad or

D871 Thinner 920 line and stir thoroughly.

equivalent.

2.  Strain material and using a 1.3-1.6 fluid nozzle on

3.  Lightly scuff all parts that are to be painted.

a conventional or H.V.L.P spray gun apply one

4.  Rinse the part with clean water and dry off.

even, medium wet coat. Allow to flash for 10-15

minutes.

5.  Apply D846 Degreasing agent for plastics directly

from container on a clean cloth, washing the

entire surface.

G456450 en

501-32-6 

Paint Preparation and Application 

501-32-6

DESCRIPTION AND OPERATION (Continued)

3.  Spray two to three medium wet coats to achieve

 CAUTION: Drying of all products may be

coverage. Allow 15-20 minutes prior to clear

accelerated by heat but to avoid distortion

coating.

unsupported bumpers should not be heated in an

4.  Mix clearcoat with D814 Plasticiser then hardener

oven or by infrared lamp above 60 degrees.

and reducer in the following ratios:

It will be necessary to remove dirt, grease, mould

release agents (if part is new) and other contaminants

D800 Clearcoat

455 - D0800 3 parts by

prior to painting.

volume

Preparation

D814 Plasticiser

499 - D0814 1 parts by

volume

1.  Remove any waterborne contaminants with PPG

D841 medium

980 - D0841 2 parts by

Bodykleen 920-35609. Mix 1 part Bodykleen to 4

hardener

volume

parts warm water.

2.  Apply mixed Bodykleen to plastic part with a

5.  Stir thoroughly and strain. Put on the air supplied

non-metallic pad such as PPG Grey Mirlon pad or

respirator.

equivalent.

6.  Using a 1.3-1.6 fluid nozzle on a conventional or

3.  Lightly scuff all parts that are to be painted.

H.V.L.P spray gun apply one even, medium wet

coat to the Base coat. Allow to flash for 3-5

4.  Rinse the part with clean water and dry off.

minutes.

5.  Apply D846 Degreasing agent for plastics directly

7.  Apply a further full wet coat. Allow a 3-5 minute

from container on a clean cloth, washing the

flash off and apply 1 full wet coat. If low baking,

entire surface.

this can be done immediately at 60

° for 30

6.  Allow 15-20 seconds contact time then dry off with

minutes. If air-drying, allow 8 hours to dry.

a separate clean cloth.

(Correct film thickness is 40-50 microns).

7.  Repeat the process three times.

Repairing Color Coat Plastic Bumpers

NOTE: Do not allow Bodykleen or D846 to dry on

surface.

Superficial damage to the paint film and or plastic

surface may be rectified by sanding and repainting.

Painting Plastic Components - General

For shallow paint damage, follow the procedure listed

Hints

under colour finishing of replacement Bumper Bars

using P800 paper to sand down imperfections and

It will be necessary to remove dirt grease, mould

using, a Grey Mirlon pad with soapy water or P1200

release agents (if part is new)and other contaminates

paper scuff, and key existing paint work.

prior to painting.

GRS Base coat and clear coat can be spot repaired

Preparation

by blending away the base coat colour but spraying

the complete bumper with clear coat. Solid colour are 1.  Remove any waterborne contaminates with Dulux

sprayed as complete panels.

Body Kleen 920-35609 1 part Body Kleen:9 parts

If the damage extends to the plastic surface this must

warm water.

be primed with D820 Plastic adhesion primer after the 2.  Apply mixed Body Kleen to plastic part with a non

correct cleaning procedure. Any small nicks or

metallic pad (3M Scotchbrite pad -or equivalent).

scrapes can be filled with PPG Iviplast 66 (A652) filler

3.  Lightly scuff all parts that are to be painted.

for plastics applied over the D820 Adhesion primer.

4.  Rinse the part with clean water and dry off.

Final sand the Iviplast 66 with P240-320 dry.

5.  Apply Universal Cleaner (920-39237)directly from

If Primer filler is required, use D839 Prima Primer

container on a clean cloth, washing the entire

flexibalised, in the ratio of:

surface.

D839 Prima

467 -D0839

4 Parts

6.  Allow 15-20 seconds contact time then dry off with

D814 Plasticiser

499- D0814

1 Part

a separate clean cloth.

D841 medium

980- D0841

1 Part

7.  Repeat process three times.

hardener

NOTE: Do not allow Body Kleen or Universal Primer

Use a 1.6-2.0 mm gun set up. Apply 2 coats

to dry on surface.

maximum with 5-7 minutes flash off between coats.

NOTE: Process to remove solvent borne

Bake for 30 minutes at 60 degrees or air dry for 8

contaminants.

hours prior to sanding. Final Sand with, P600 wet or

P400dry for solid colours, and P800 wet or P500-600

Plastics Including Nylon

dry for metallic or pearl colours.

D820 Plastic adhesion Primer 449-D0820 (Primer is

transparent red colour)

G456450 en

 

 

 

 

 

 

 

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