Flexible Panel Repair System

Procedure - Full Panel

Full panel repairs must be performed; spot repairs are not recommended.

CAUTION: There are a number of flexible paint systems available for service use; however, many require additives containing isocyanates. It is essential that all recommendations and warnings listed on the container label for materials selected be followed.

It is mandatory that adequate respiratory protection be worn. Examples of such protection are: 3-M models No.6984 and No.6986 disposable respirators.

Such protection should be worn during the entire paint process. Persons with respiratory problems, or those allergic to isocyanates must not be exposed to isocyanate vapors or spray mist.

1. Flexible Undercoat Requirements

If the part to be painted is a replacement, it will be factory primed with an elastomeric enamelbased primer. As long as the original primer is not scratched to expose the plastic substrate, all that is required is to solvent clean, sand with No. 400 paper or a red "Scotch-Brite" pad, reclean and apply elastomeric color.

However, if the plastic substrate is exposed or the part is repaired with flexible filler material, a flexible primer surfacer must be used to provide the filling properties required. This is to prevent a "bull's-eye" condition or highlighting of the bare substrate or filler repair after color is applied.

Prepare flexible primer surfacer as follows:

a. Clean the entire part with a wax, grease and silicone removing solvent applied with a water dampened cloth. Wipe dry.

NOTE: The step above begins to prepare the entire part for color coats. Spot repair is not recommended because dry spray at the blend area of applied elastomeric color does not "wet out" satisfactorily.

b. Featheredge the scuff or filler repair with No. 320 sandpaper. Blow off dust and tack wipe.

c. Mix and apply four medium-dry coats of flexible primer surfacer. Follow manufacturer's instructions for specific mix ratios and additives.

NOTE: Use a fast evaporating thinner as recommended to reduce the primer-surfacer and do not apply excessively wet coats. Bare flexible plastic surface and/or flexible filler materials have a tendency to swell from thinner absorption, resulting in a visible or "highlighted" repair.

d. Allow to dry at least one hour and block sand with No. 400 sandpaper. Sand the entire part with No. 400 sandpaper or red "Scotch-Brite" pad to remove all gloss in preparation for color application.

When paints are modified with a flex additive, the possibility of mixture "pot life" exists; therefore, spray equipment should be cleaned immediately after use.

2. Body Color with Flexible Additive Systems

There are several flexible topcoat systems available for the painter's selections; in most cases, it is a matter of personal preference. Basecoat/clearcoat material can be either enamel or lacquer-based.

Some manufacturers do not recommend the use of flex additives in their basecolor material, but do recommend its use for their lacquer clearcoat.

a. Thoroughly sand the entire part with No. 400 sandpaper or red "Scotch-Brite" pad to remove ALL gloss. Reclean the part.

b. Mix the base color, flexible additive if recommended, and thinner. Follow manufacturer's label instructions.

c. Apply a sufficient number of coats to achieve complete hiding and color match. Allow flash time between coats.

d. Allow the base color coat to dry 30-60 minutes before applying the clearcoat. DO NOT sand the basecoat before applying the clearcoat.

NOTE: If sanding of the basecoat is necessary to remove imperfections such as dirt or sags, sand with No. 400 grit or finer sandpaper and reclean the area(s). Apply one additional coat of base material and let dry.

3. Clearcoat Application

a. Mix and reduce clearcoat (lacquer or enamel) material as per label instructions.

NOTE: Use flex additive if recommended by paint source.

b. Strain the mixture and apply 2-3 coats with 35-40 lbs. air pressure at the gun.

c. Allow each coat to flash completely before applying the next coat. Allow at least 4 hours air dry time or force dry for 30 minutes with a heat lamp at 180 degrees Fahrenheit before putting into service.

NOTE: Compounding is not recommended when a flexible additive is used in the top coat paint material. The mixture will dry with acceptable glow.

Compounding dulls the gloss of elastomeric finishes, causing a flat appearance. The finish cannot be brought back to the same gloss level without applying more paint.