xvii Bolted Part Replacement Steps ...................... 211 Read the Estimate .............................................. 211 Analyze the Damage ......................................... 211 Plan the Repair ................................................... 211 Remove the Damaged Parts .............................212 Fit Up ...................................................................212 Final Assembly ...................................................213 Replacing Specifi c Bolted Parts ......................213 Steel Bumpers .....................................................214 Plastic Bumpers ..................................................216 Installing a Plastic Bumper ...............................218 Header Panel ......................................................218 Fenders ................................................................219 Hood ....................................................................223 Doors ...................................................................226 Deck Lid ..............................................................230 Rear Hatch ..........................................................232 Sliding Door ........................................................233 Pickup Bed ..........................................................234 CHAPTER 11 Welded and Bonded Nonstructural Panel Replacement 239 Introduction .......................................................240 Welded and Bonded Nonstructural Panel Replacement Steps ............................240 Reading the Estimate.........................................240 Analyzing the Damage .....................................240 Planning the Repair ...........................................241 Accessing the Damage ......................................242 Rough Cutting ....................................................243 Final Cutting .......................................................245 Preparing Panels ................................................246 Fit Up ...................................................................248 Joining .................................................................249 Rivet Bonding .....................................................250 Finishing ..............................................................250 Replacing Specifi c Nonstructural Panels .....252 Quarter Panel Replacement .............................252 Roof Replacement ..............................................255 Rear Body Panel Replacement .........................258 Bed Side Replacement .......................................259 Cab Corner Replacement ..................................261 Van Side Replacement .......................................262 Door Skin Replacement ....................................262 Patch Panel Installation .....................................266 CHAPTER 12 Plastic Repair 271 Introduction .......................................................272 Classifying Plastics ...........................................273 Tools and Materials ...........................................273 Die Grinder .........................................................273 Plastic Welder .....................................................275 Flexible Putty/Adhesives .................................276 Adhesion Promoter ...........................................277 Mesh ....................................................................277 Fiberglass ............................................................278 Plastic Repair Steps ..........................................278 Read the Estimate ..............................................278 Remove the Damaged Part ...............................278 Clean the Repair Area .......................................279 Identify the Plastic to Be Repaired ..................279 Plan the Repair ...................................................279 Align the Damaged Parts .................................280 Make the Repair .................................................281 Finishing ..............................................................286 Repairing Specifi c Types of Damage ............287 Flexible or Semi-Rigid Non-Olefi n Plastic Gouge (RIM, RRIM, Xenoy, GTX, Pulse, Urethane) .........................................................287 Flexible or Semi-Rigid Tear—Binding Repair (Urethane, RIM, RRIM, Xenoy, GTX, Pulse, TPO, TEO, PP) ...........................287 Olefi n Dent (TPO, TEO) ....................................288 Olefi n Gouge (TPO, TEO) .................................289 Olefi n Tear—Bonding Repair (TPO, TEO) .....289 Thermoplastic Break (Xenoy, ABS, TPO, TEO, PP, PE) ....................................................290 SMC or FRP Scratch ...........................................291 SMC Break ..........................................................291 SMC Splice ..........................................................292 FRP Break ............................................................293 CHAPTER 13 Glass 297 Introduction .......................................................298 Types of Glass ....................................................298 Movable and Fixed Glass ................................299