Subaru Legacy (2005 year). Manual - part 994

EI-33

EXTERIOR/INTERIOR TRIM

Front Bumper

2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER

NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re-
stored to its original condition. Damages limited to the shallow scratches that cause only a change in the lus-
ter of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
1) Minor damage of only a change in luster of the bumper caused by a light touch
Almost restorable.

2) Deep damage caused by scratching with fences
A dent cannot be repaired but a whitened or swelled part can be removed.

Pro-

cess

No.

Process name

Job contents

Cleaning

Clean the area to be repaired using water.

Sanding

Grind the repairing area with #500 sand paper in a “feathering” motion.

Finish

Resin section

Coated section

Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.

Perform either the same process as for the
resin section or process No. 18 and subse-
quent in the 3) section, depending on the
degree and nature of damage.

Polish the waxed area with a clean cloth after 5
to 10 minutes.

Pro-

cess

No.

Process name

Job contents

Cleaning

Clean damaged area with water.

Removal of dam-
aged area

Cut off protruding area, if any, due to collision, using a putty knife.

Sanding

Grind the affected area with #100 to #500 sand paper.

Finish

Resin section

Coated section

Same as Process No. 3 in the 1) section.

Perform Process No. 12 and subsequent oper-
ations in the 3) section.

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EXTERIOR/INTERIOR TRIM

Front Bumper

3) Deep damage such as a break or hole that requires filling
Much of the peripheral grained surface must be sacrificed for repair. The degree of restoration is not really
worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)

Pro-

cess

No.

Process name

Job contents

Bumper removal

Remove the bumper as required.

Removal of parts

Remove the parts built into bumper as required.

Bumper placement

Place the bumper on a paint worktable as
required.
It is recommended to use the paint worktable
conforming to internal shape of bumper.

(1) Bumper
(2) Bumper cross-section view

Surface prepara-
tion

Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol, etc.)

Cutting

If nature of damage are cracks or holes, cut a
guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the bumper
base surface. Then, bevel or “vee-out” the
affected area using a knife or grinder.

(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)

Sanding (I)

Grind beveled surface with sand paper (#40 to #60) to smooth finish.

Cleaning

Clean the sanded surface with the same solvent as used in Process No. 4.

Temporary welding

Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.

(1) Welded point (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:
• Do not melt welding rod until it flows out. This results in reduced strength.
• Leave the welded spot unattended until it cools completely.

EI-00234

(2)

(1)

EI-00235

(4)

(2)

(1)

(3)

EI-00236

(1)

(2)

(3)

EI-35

EXTERIOR/INTERIOR TRIM

Front Bumper

Welding

Using a heater gun and PP welding rod, weld the beveled spot while melting both the rod and
damaged area.

(1) Welding rod
(2) Melt hatched area
(3) Cross-section view
NOTE:
• Melt the areas indicated by hatched area.
• Do not melt the welding rod until it flows out, in order to provide strength.
• Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
• Leave the welded spot unattended until it cools completely.

Sanding (II)

Remove excess part of the weld with a putty knife. If a drill or disc wheel is used instead of the
knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher
rpm will cause the PP substrate to melt from the heat.

Sand the welded spot smooth with #240 sand paper.

Masking

Mask the black substrate part using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent

Cleaning/ degreas-
ing

Completely clean the entire coated area, using solvent similar to that used in Process No. 4.

Primer coating

Apply a coat of primer to the repaired surface and its surrounding area. Mask these areas, if nec-
essary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply coat of primer at a spraying pressure of 245 — 343 kPa (2.5 — 3.5 kgf/cm

, 36

— 50 psi) with a spray gun.

Leave unattended

Leave the repaired area unattended at 20

°C (68°F) for 10 to 15 minutes until primer is half-dry.

NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth with alcohol. (Do not use
thinner. The coated area may be melt.)

Primer surfacer
coating

Apply primer surfacer to the repaired area two to three times at an interval of 3 to 5 minutes.
Recommended surfacer:
• UPS 300 Flex Primer
• No. 303 UPS 300 Exclusive hardener
• NPS 725 Exclusive Reducer (thinner)
• Mixing ratio:
2:1 (UPS 300:No. 303)
• Viscosity: 12 — 14 sec. /20

°C (68°F)

• Coating film thickness: 40 — 50

Pro-

cess

No.

Process name

Job contents

(1)

(2)

(3)

EI-00237

EI-00042

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EXTERIOR/INTERIOR TRIM

Front Bumper

Drying

Allow the coated surface to dry for 20 minutes at 20

°C (68°F) or 30 minutes at 60°C (140°F).

Sanding (III)

Sand the coated surface and its surrounding area using #400 sand paper and water.

Cleaning/ degreas-
ing

Same as Process No. 12.

Top coat (I)

Non-colored

Metallic paint

Use a “block” coating method.
• Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixing ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3:1
• Viscosity: 11 — 13 sec. /20

°C (68°F)

• Coating film thickness: 40 — 50

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

, 36 — 50 psi)

°C (68°F)

• Coating film thickness: 20 — 30

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

, 36 — 50 psi)

Leave unattended

Not required.

Leave unattended at 20

°C (68°F) for at least 10

minutes until the topcoat is half-dry.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the repaired area.

Top coat (II)

Not required.

Apply clear coat three times at an interval of 3
to 5 minutes.
• Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixing ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3:1
• Viscosity: 10 — 13 sec. /20

°C (68°F)

• Coating film thickness: 20 — 30

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

, 36 — 50 psi)

Drying

Allow the coated surface to dry for 2 hours at 20

°C (68°F) or 30 minutes at 60°C (140°F).

NOTE:
Do not allow the temperature to exceed 80

°C (176°F). Otherwise PP substrate may be deformed.

Inspection

Carefully check the condition of repaired area.

Masking removal

Remove the masking tape applied in Process No. 11 and 13.

Parts installation

Install parts on the bumper in reverse order of removal.

Bumper installation

Install the bumper.

Pro-

cess

No.

Process name

Job contents

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