77
PANEL REPAIRS
4
SEALING AND CORROSION PROTECTION
Fitting Approved Accessories
When fitting accessories it is important that the
vehicle’s corrosion protection is not affected, either by
breaking the protective coating or by introducing a
moisture trap.
DO NOT screw self-tapping screws directly into the
body panel but fit plastic inserts first. Protect the
edges of holes drilled into panels, chassis members
and other body parts with a suitable zinc rich or acid
etch primer, followed by a protective wax coating
brushed onto the surrounding area.
DO NOT affix unpainted metal surfaces of any
accessory directly to the vehicle bodywork unless they
are suitably protected. Where metal faces are bolted
together always interpose a suitable interface material
such as weldable zinc rich primer, extruded strip or
zinc tape.
Cavity Wax Injection
Box sections treated with cavity wax are shown in this
section. Repairs affecting these areas must include
re-treatment with an approved cavity wax, using the
access points ilustrated. In addition, all interior
surfaces which have been disturbed during repairs
must be wax injected whether they have been treated
in production or not. This includes all box members,
cavities, door interiors etc. It is permissible to drill
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable zinc
rich primer, brushed with wax and then sealed with a
rubber grommet.
Prior to wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using a
compressed air supply.
Carry out wax injection after final paint operations.
During application, ensure that the wax covers all
flange and seam areas and that it is applied to all
repaired areas of both new and existing panels.
NOTE: Apply cavity wax AFTER the final
paint process and BEFORE refitting of any
trim components.
It should also be noted that new panel assemblies and
body shells are supplied without wax injection
treatment which must be carried out after repairs.
Effective cavity wax protection is vital. Always observe
the following points:
•
Complete all finish paint operations before
wax application.
•
Clean body panel areas and blow-clean
cavities if necessary, before treatment.
•
Maintain a temperature of 18˚ C during
application and drying.
•
Check the spray pattern of injection
equipment.
•
Mask off all areas not to be wax coated
and which could be contaminated by wax
overspray.
•
Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
•
Move door glasses to fully closed position
before treating door interiors.
•
Treat body areas normally covered by trim
before refitting items.
•
Check that body and door drain holes are
clear after the protective wax has dried.
•
Keep all equipment clean, especially wax
injection nozzles.