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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

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    							77PANEL REPAIRS
    16
    SEALING AND CORROSION PROTECTION Rear door
    M77 2075A
    B - B
    1
    A
    B
    B
    A
    222
    2
    A - A
    Section A-A and B-B show application areas of cavity wax for the rear door. Arrows 1 and 2 show the application
    holes. 
    						
    							PANEL REPAIRS
    17
    SEALING AND CORROSION PROTECTION SEALANTS AND ADHESIVES
    Structural Adhesive
    Metal-to-metal adhesive is applied to critical joint
    areas during factory assembly. The material used is a
    high-temperature, heat cured, nitrile phenolic which
    serves both to bond two metal surfaces and also to
    seal the joint against ingress of dust, water, petrol and
    fumes. This material is not suited for service use, and
    should be substituted in repair using a suitable
    medium strength adhesive.
    When separating a joint treated with metal-to-metaladhesive, to avoid distortion it is recommended that
    the joint be gently heated until the bond weakens
    sufficiently to permit panel separation.
    NOTE: DO NOT carry out MIG welding on a
    joint area which has been treated with
    metal-to-metal adhesive until all traces of
    adhesive have been removed.
    The following Illustrations show the treatment areas
    for Structural Adhesive.
    All areas symmetrically opposite to those shown are
    also treated.
    Body side capping
    Structural adhesive applied around body side lower fixing holes 
    						
    							77PANEL REPAIRS
    18
    SEALING AND CORROSION PROTECTION Seam Sealers
    A heat cured, PVC Plastisol sealer is applied to joint
    areas during factory assembly. This material is not
    suitable for service use.
    Carry out seam sealing after the application of primer
    and before the surfacer and final paint coats. Ensure
    that surfaces are first cleaned of all grease and oil.
    Apply the sealer material to the joint as a bead, either
    by hand or using an applicator gun. Where necessary,
    brush sealer well into the joint and wipe smooth using
    a cloth soaked with solvent such as Shell SBP3. This
    will ensure an acceptable cosmetic finish.
    Apply sealer to ALL accessible joints following repair
    work. Be aware that damage to a vehicle can often
    result in deflection to those areas of the body which
    are remote from the impact. The sealers in these
    areas can therefore be disturbed by subsequent
    straightening and repair operations. Check joints in
    the vicinity of the area undergoing repair for evidence
    of cracked sealer, clean them out as required and
    re-treat them with fresh sealer using the following
    procedure:
    Clean the affected joint or seam and
    re-treat any exposed metal areas with a
    suitable etch phosphate primer.
    Treat affected area with an acid-etch
    primer.
    Apply appropriate seam sealer as
    necessary.
    Apply appropriate colour coat (and
    underbody sealer as applicable).
    Where joints are inaccessible following the
    reassembly or fitment of components, ensure that a
    paste-type sealer is applied to such joints. Certain
    seams also become inaccessible after the completion
    of panel repairs. In such instances the paint process
    should be carried out and sealers applied before final
    assembly.Provided access is adequate, apply the sealer to both
    sides of the repair joint. Where access is limited to
    one side only (e.g. box sections), inject the affected
    box member with cavity wax.
    CAUTION: ALWAYS deploy an extractor
    unit to remove toxic fumes when using
    oxy-acetylene equipment to remove panels
    treated with wax and sealers.
    The following Illustrations show the treatment areas
    for Seam Sealing. 
    						
    							PANEL REPAIRS
    19
    SEALING AND CORROSION PROTECTION Seam sealing on bulkhead assembly - front view
    All areas symmetrically opposite to those shown are also treated.
    Seam sealing on bulkhead assembly - rear view 
    						
    							77PANEL REPAIRS
    20
    SEALING AND CORROSION PROTECTION Seam sealer on body side assembly
    Seam sealer on front door
    NOTE: Seam sealer to be wiped after application for cosmetic purposes. 
    						
    							PANEL REPAIRS
    21
    SEALING AND CORROSION PROTECTION Seam sealer on rear end assembly
    CAUTION: Do not block drain holes when applying seam sealer. 
    						
    							77PANEL REPAIRS
    22
    SEALING AND CORROSION PROTECTION Seam sealer on roof assembly 
    						
    							PANEL REPAIRS
    23
    SEALING AND CORROSION PROTECTION PUTTY APPLICATION AREAS
    The following Illustrations show the treatment areas for Putty application.
    All areas symmetrically opposite to those shown are also treated.
    Putty location on bulkhead assembly
    Putty location on rear end 
    						
    							77PANEL REPAIRS
    24
    SEALING AND CORROSION PROTECTION Putty location on underside of vehicle 
    						
    							PANEL REPAIRS
    25
    SEALING AND CORROSION PROTECTION Putty location on front door 
    						
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