2 part Panel Bond procedure |
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Posted: 08-April-2012 at 3:51PM |
here is a procedure I wrote in 2005 for the Moparts.com forum for
bonding panels with the 2 part panel bond adhesive Complete Quarter Panel Bonding (factory style) Step 1. Remove all trim and any glass that needs to be removed. Step 2. Jack vehicle up in rear and support body with jack stands(try to make car level) remove wheel. Step 3. Look at new panel and determine attachement points and seams. Using a grinder(air powered is best) with 24or 36 grit disc,grind paint off at any seams where new panel must attach, grinding lead out of seam exposing spot welds(not necessary on partial 1/4) Step 4.Using a spot weld drill bit,drill out spot welds. Drilling spot welds A. Using a wire wheel on drill or die grinder remove paint exposing any spotwelds that you may not see,or covered with paint on all seams. B. using a centerpunch,punch the center of all spotwelds. C.Using a spotweld cutter(Blair,Blair RotaBroach) Drill panel till it goes thru one thickness of metal.Drilling out each weld. Spotwelds are located on all seams,wheel opening, and joints.Do Not Drill Thru Metal All The Way. D. Using a flat scraper or chisel and hammer, slide between the two metals and pry the two layers of metal.If metal doesn't pop apart,look for a weld you missed or not drilled deep enough. you may have to chisel between welds to release if small bit of metal is holding panel. Step 5. After drilling all welds look for any spots that may have been brazed(brass welding) if you find take a torch heating brass and using a small prybar or scraper lift on panel while heatng(Caution,Do Not Get Metal Red Hot) torch should melt brass and release panel. Step 6.Remove old skin. Taking a hammer and dolly.Straighten any edges that may have gotten bent during removal. Step 7.Grind smooth and remove paint from all welding flanges and seams. Step 8.Fit new panel in place making sure edges and body lines match adjacent panels. Hold in place using clamps or cleeko pins. Cleeko's are good for realigning panel during bonding process. On the back seam along rear bodypanel,drill some 5/16ths holes into 1/4 skin for plug welding it to rear body panel later. (stitch welds can be used instead also) Step 9.Remove new panel and place face down. Take ginder and remove black E-coat around inside edges(panel mateing surface)grind coating off about half to three quarters wide. Step 10.Apply a bead of Panel Bonding Adhesive around inside edge of 1/4 skin, using a plastic spreader, spread adhesive smooth covering all bare metal. Step 11. Apply bead of adhesive on body flanges where 1/4 skin meets,and smooth also like above. Step 12. Apply 1/8in. bead of adhesive around body flange surfaces. Step 13. Place 1/4 skin on car aligning panel to adjacent panels,making sure gaps are even and bodylines line up.Then clamp in place using vice grips or cleeko holding pins. Let panel dry according to adhesive instructions. Plug or stitch weld the rear body joint after the adhesive has cured. Partial 1/4 skin supplement A. When removing old 1/4 skin cut along edge of 1/4 leaving approx. 2 inches extra metal underneath where top edge of partial skin stops. B. Remove old skin and place partial skin in place,aligning panel to adjacent panels. C. Taking 3/4 masking tape,tape along edge of partial skin (tape above partial 1/4 edge) D. This step requires a flanging tool (Air operated or hand pliers)Flange a piece of scrap metal.Measure from edge of metal to where crimp in metal is.Using this measurement mark old 1/4. E. Measure from edge of tape down to the above crimp width measurement.cut excess metal off to bottom of new mark. F. Flange metal along length of old 1/4 at edge. G. Place new partial skin in place,align panel and check to make sure edge of panel sits flush in flange.(trim edge of 1/4 skin if necessary) H. Clamp new panel in place(aligning gaps and body lines) drill 1/8th in. holes thru 1/4 skin along seam halfway down from edge of old and top of new panel.Secure with cleeko pins or screws. I. remove panel and grind coating off inside of partial 1/4 approx. 1/2 in. down from edge. grind any paint along old 1/4 edge. J. Apply a liberal amount of adhesive to both old 1/4 and new skin using same method as above mentioned process. apply the 1/8th in. bead of adhesive along flange and place 1/4 skin in place. K. align skin and put cleeko's or screws in excisting holes along seam.Use Above method for attching the other areas of 1/4 skin. Let adhesive dry then smooth seam with grinder. (Weld rear body seam as mentioned in above) L. After removeing cleeko's and smoothing seam with grinder,apply a coat of either Duraglass filler or All Metal filler over seam. smooth seam straight with sanding block and 36 grit sand paper. M. Finish seam with body filler then sand and prime panel.(Inside trunk seam of 1/4 can be smoothed over with above method then sprayed with Paintable Rubberized Undercoating & Painted) Tools and Materials Required 4-5 in. grinder with 24or 36 grit discs Panel Cutter(cut-off tool or shear type) Flat scraper or chisel Body Hammer and Metal dolly SpotWeld Cutter( Blair double blade or Blair RotaBroach Cutters work best) Cleeko panel holding pins or 1/8th in.screws Cleeko Pliers Flange Tool (Air operated or hand pliers) SEM or 3M Panel Bonding Adhesive & Applicator gun (SEM applicator gun is cheapest-Approx. $60) (3M App. Gun is Approx. $130-$150) Wire Feed welder for plug or stitch welding rear body seam. 3/4 in. Tape Pencil or Marker(Sharpie) Sanding Block and 36 grit paper Duraglass or All Metal filler Body filler and Sandpaper Paintable Rubberized Undercoating |
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most people rather have a fully welded on quarter skin but I wrote this for people who don't have welding experience as an alternative for replacing a panel
reason why there is a complete factory style quarter replacement method as some of the Mopar's you can by full factory style quarter skins unlike our Torino's where we can only get partial quarters also you can make patch panels and bond those on as well and not have to weld them.
Edited by 72 GTS 429 - 08-April-2012 at 3:59PM |
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