xvii
Copyright Goodheart-Willcox Co., Inc.
Bolted Part Replacement Steps . . . 209
Read the Estimate . . . . . . . . . . . . 209
Analyze the Damage . . . . . . . . . . 209
Plan the Repair . . . . . . . . . . . . . 209
Remove the Damaged Parts . . . . . . . 210
Fit Up . . . . . . . . . . . . . . . . . 210
Final Assembly . . . . . . . . . . . . . 211
Replacing Specifi c Bolted Parts . . . 211
Steel Bumpers . . . . . . . . . . . . . 212
Plastic Bumpers. . . . . . . . . . . . . 214
Header Panel . . . . . . . . . . . . . . 216
Fenders . . . . . . . . . . . . . . . . 218
Hood . . . . . . . . . . . . . . . . . 221
Doors . . . . . . . . . . . . . . . . . 225
Deck Lid. . . . . . . . . . . . . . . . 228
Rear Hatch . . . . . . . . . . . . . . . 230
Sliding Door . . . . . . . . . . . . . . 231
Pickup Bed. . . . . . . . . . . . . . . 232
CHAPTER
11
Welded and Bonded
Nonstructural
Panel Replacement 237
Introduction . . . 238
Welded and Bonded Nonstructural
Panel Replacement Steps . . . 238
Reading the Estimate . . . . . . . . . . 238
Analyzing the Damage . . . . . . . . . 238
Planning the Repair . . . . . . . . . . . 239
Accessing the Damage . . . . . . . . . . 240
Rough Cutting . . . . . . . . . . . . . 240
Final Cutting . . . . . . . . . . . . . . 243
Preparing Panels . . . . . . . . . . . . 244
Fit Up . . . . . . . . . . . . . . . . . 244
Joining . . . . . . . . . . . . . . . . 246
Finishing. . . . . . . . . . . . . . . . 248
Replacing Specifi c Nonstructural
Panels . . . 249
Quarter Panel Replacement . . . . . . . 249
Roof Replacement. . . . . . . . . . . . 253
Rear Body Panel Replacement . . . . . . 255
Bed Side Replacement . . . . . . . . . . 257
Cab Corner Replacement. . . . . . . . . 258
Van Side Replacement . . . . . . . . . . 260
Door Skin Replacement . . . . . . . . . 260
Patch Panel Installation . . . . . . . . . 264
CHAPTER
12
Plastic Repair 269
Introduction . . . 270
Classifying Plastics . . . 271
Tools and Materials . . . 271
Die Grinder . . . . . . . . . . . . . . 271
Plastic Welder . . . . . . . . . . . . . 273
Adhesives . . . . . . . . . . . . . . . 274
Adhesion Promoter . . . . . . . . . . . 275
Mesh . . . . . . . . . . . . . . . . . 275
Fiberglass . . . . . . . . . . . . . . . 276
Plastic Repair Steps . . . 276
Read the Estimate . . . . . . . . . . . . 276
Remove the Damaged Part . . . . . . . . 276
Clean the Repair Area . . . . . . . . . . 277
Identify the Plastic to Be Repaired . . . . . 277
Plan the Repair . . . . . . . . . . . . . 277
Align the Damaged Parts . . . . . . . . 278
Make the Repair . . . . . . . . . . . . 279
Finishing. . . . . . . . . . . . . . . . 284
Repairing Specifi c Types of Damage . . . 285
Flexible or Semi-Rigid Non-Olefinfi
Plastic Gouge (RIM, RRIM, Xenoy,
GTX, Pulse, Urethane) . . . . . . . . . 285
Flexible or Semi-Rigid Tear—Binding
Repair (Urethane, RIM, RRIM, Xenoy,
GTX, Pulse, TPO, TEO, PP) . . . . . . . 285
Flexible or Semi-Rigid Non-Olefinfi
Plastic Tear—Adhesive Repair (RIM,
RRIM, Xenoy, GTX, Pulse, Urethane). . . 286
Olefi Gouge (TPO, TEO) . . . . . . . . 287 fin
Olefi Tear—Bonding Repair fin
(TPO, TEO) . . . . . . . . . . . . . . 287
Thermoplastic Break (Xenoy, ABS,
TPO, TEO, PP, PE) . . . . . . . . . . . 288
SMC or FRP Scratch . . . . . . . . . . . 289
SMC Break . . . . . . . . . . . . . . . 289
SMC Splice. . . . . . . . . . . . . . . 290
FRP Break . . . . . . . . . . . . . . . 291