Body Repair Manual

Refinishing Procedures
1. Featheredging (polishing damaged areas)
-1. Damage to metal surface
• Sand the damaged area flat and smooth with a
double action sander and #60 or #80 disc paper.
• Sand the boundary between the metal surface and
undercoat with a double action sander and #180 or
#280 disc paper. Try to sand a larger area than the
damage.
NOTE:
• Make sure there is no height difference between
the metal surface and undercoat.
• If a double action sander is not available, use a rubber
block and wrap sandpaper around it to sand the
surface.
To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting or
grinding.
-2.Damage to Undercoat
Intermediate coat
Top coat
Paint coat on replacement parts
Sand the damaged surface flat and smooth with a
double action sander and #280 or #320 paper.
NOTE:
• If a double action sander is not available, use a rubber
pad and wet or dry sand the surface with #280, #320,
#400 or #600 sandpaper.
• After sanding, check that the surface is flat ant
smooth.
• Perform the operations under Item 1-1 for the areas
where parts are welded to the body.
2. Preparation of metal surface.
Remove all corrosion from the damaged area using a
#180 or #280 paper.
3. Air Blowing/Degreasing
Air blow the sanded area, then degrease with a wax and
grease remover (for USA usage-Dupont 38125 Enamel
Reducer).
• Do not use high air pressure: Use only an ap-
proved, 210 kPa (2.1 kgf/cm
2
, 30psi) air nozzle.
• Wear goggles or safety glasses to prevent eye
injury.
4. Treatment of metal surface
• Brush or spray a solution of chrome phoshate or
washer primer on the exposed metal surface.
• Use the following materials to treat the metal sur-
face:
• Metal conditioner (kamsai Paint) (for USA usage-
Duporit 2415 Kwik-Prep TM)
• ACP agent (Nippon Paint)
• Precoat (Isam Paint) (for USA usage-Dupont 6155/
6165 Vari Prim Self-Etching Primer TM)
NOTE:
• Follow the manufacturer's instructions.
• Treat the metal surface, as much as possible, to
provide a better bonding surface for the subsequent
paint.
5. Application of Filler
Drying
Sanding
• Small cracks or pinholes in the sheet metal should be
repaired with a filler and sanded flat and smooth.
NOTE:
• Mix the putty with the hardener in the correct ratio.
• Follow the filler manufacturer's instructions.
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