PANEL SURFACE PREPARATION RAM Pickup 1500

PANEL SURFACE PREPARATION

If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area should be stripped of paint and freed from wax and oil. Sand surfaces around repair area with 80 -120 grit sandpaper, or equivalent, to assure adhesion of repair materials.

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A panel that has extensive puncture type damage can be repaired by cutting out the damaged material. Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20° to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas.

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A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following operation if required

1. Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required.
2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area.
3. Apply a liberal coat of adhesive over the reinforcement mesh. If necessary apply a second or third coat of adhesive and mesh after first coat has cured. The thickness of the patch should be the same as the repair area.
4. After patch has cured, peel waxed paper or plastic from the back of the patch.
5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength.

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1. Make a paper or cardboard pattern the size and shape of the cutout hole in the panel.
2. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces.
3. Using the pattern as a guide, cut the patch to size.
4. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout.
5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole.
6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout.
7. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side.
8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper.
9. Mix enough adhesive to cover one side of all support squares.
10. Apply adhesive to cover one side of all support squares.
11. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares. 1 - CUTOUT 2 - SUPPORT SQUARES
12. Position patch in cutout (1) against support squares (2) and adjust patch until the gap is equal along all sides.
13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch. 1 - APPLICATOR 2 - SUPPORT SQUARES 3 - ADHESIVE
14. Apply a coat of adhesive (3) to the exposed ends of the support squares (2). 1 - PATCH 2 - GAP
15. Install screws to hold the patch (1) to support squares. Tighten screws until patch surface is flush with panel surface.
16. Allow adhesive to cure, and remove all screws. 1 - PATCH 2 - GAP 3 - DISC GRINDER
17. Using a 125 mm (5 in.) 24 grit disc grinder (3), grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 75% -80% deep (original material thickness) path across the gaps (2) around the patch (1). With compressed air, blow dust from around patch. 1 - GROUND DOWN AREA 2 - PATCH 3 - MESH
18. Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch.
19. Mix enough adhesive to cover the entire patch area. 1 - ADHESIVE 2 - MESH 3 - PATCH 4 - SPREADER
20. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair.