FOAM RUBBER REPLACEMENT
Install the foam rubber replacement in the cavity to counter sound spreading through the body.
The foam rubber replacement is a wax treated foam ball (P/N 681 7640) that can be compressed and inserted between the panel sections. More than one foam ball can be used if one is not sufficient.
Scheme 38
Aligning
- Galvanized body components can be aligned in the usual way, but avoid using a body file. Use a sanding block or grinding disc with 80-grade paper instead
- Apply soldering paste in the usual way
- The soldering paste removes the galvanizing and adheres to the bare metal
- Always finish with 120-grain paper to prepare for spray painting.
Note. Protect the galvanized layer as much as possible, as it is part of the rust protection.
Scheme 39
Welding
- Galvanized body components can be welded using MAG and resistance spot welding
- Protect the galvanized layer when preparing to weld.
Note. Use welding primer between the joins. Use point extraction .
- When resistance spot welding , the electrodes must be pressed together for a longer period than for untreated metal
- Voltage must also be increased slightly.
Note. Check welds carefully. Surfaces must be clean when resistance spot welding. Clean the surfaces using Scotch-Brite or similar. This protects the zinc coating and phosphate coating on the metal.
Scheme 40
Base filling
- After aligning galvanized panels use plastic filler in the same way as on ordinary body panels
- Not all types of filler can be used directly on galvanized metal
- Volvo has developed a special filler . This filler can be used on both aluminum and conventional body panels. No primer is necessary .
When applying plastic filler
- Apply filler
- Do not damage the galvanized layer
- Filler thickness max 1 mm
- Sand off the old paint
- Old paint need not be sanded off if damage is superficial. Matt using 120-grain paper.
- Limit the area being sanded. Remember that it will need to be spray painted later.
- Always finish with 120-grain paper to prepare for spray painting.
