Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Large Repair Areas

A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating.

NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3.

1. Use a heat gun or lamp to soften the vinyl coating until it is pliable.
2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc).

NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL.

3. Make the necessary repairs to the sheet metal.