Roof Panel Repair
Roof Panel Repair
Overview:
When evaluating a corrosion condition on a roof panel you need to take into consideration things like extent of the condition. Will you need to remove the windshield to do the repair? Can a repair be made without removing the headliner? What type of joint would be best suited for this particular repair?
Roof Panel Repair using a Backer Panel:
1. Remove all parts necessary to access the damaged area.
2. Remove all the corrosion from the panel being repaired. If there is any corrosion left behind, even if it's deep in the pitted areas the corrosion will return.
Illustration D:
3. All paint, primer, adhesive, and any other protective coatings must be removed from all mating surfaces prior to application of any adhesive for the backer panels. Grind a 2.5cm (1 inch) contact area on all panels where you will do your backer panel bond. The metal should be bare and shiny in appearance. The panels to be used as the backer panels must also be free of all coatings. Bevel the backer panel to prevent moisture or condensation from collecting between the panels.
Illustration E:
4. Pre-fit the backer panels to the roof and the insert patch to ensure a proper fit. If screws Will be required to hold the backer panels and the inseit in place during application they Should be used during the dry fit.
5. Using Mopar (part # 05083855AA) / Fusor #112B dispense a small amount of adhesive with out the tip to assure there is an even flow of adhesive from booth sides of the cartndge. Once you are sure there is even flow install the mixing tip and pump the adhesive through the mixing tip.
Note: Apply the structural adhesive to all bare metal at the bond area The adhesive has corrosion resistant properties built-in to protect the metal from corrosion.
6. Apply 3/8 to 1/2 inch of Mopar / Fusor #112B to the mounting area of the insert panels. From this point you will have approximately 70 minutes @ 21 °C (70 °F) to apply the adhesive and assemble the components.
Illustration F:
7. Use a body filler applicator to smooth the adhesive and to cover all bare metal to prevent conosion.
8. Position the backer panels into place using the clamps and/or screws from the prior dry fit process.
9. You may need to smooth or finesse the adhesive at the bond surface prior to installing the insert/repair panel.
10. Apply a small amount of adhesive to the underside of the insert/repair panel at the bare metal spots to ensure there will be corrosion protection.
11. Secure the insert/repair panel in place tising clamps and/or screws from the dry fit process.
12. Remove all excess adhesive material from the work area.
13. Once the adhesive has achieved handling strength in approximately 2 1/2 hours remove the clamps and/or screws.
14. When the adhesive has reached full cure, if screws were used bevel the screw-holes and prepare the joint and screw holes for the application of waterproof fiber-filled body filler. Complete repair using conventional body filler.
15. Refinish following paint manufacturers recommendations.