for reinforcements. If this occurs, the plastic may swell in the area of repair and cause the repair to fail. Remove cleaners and water quickly and use air and heat to speed up drying.
NOTICE: During the repair of many plastics and particularly polyolefin plastics, an adhesion promoter must be applied to the substrate to allow repair materials and paint to bond correctly. Reapplication is required when grinding or sanding through the sealer or primered layers.
NOTE: When possible, it is recommended to carry out as much of the plastic repair as possible on the vehicle. Parts mounted on the vehicle are held in correct alignment throughout the repair. Attempting to repair the part off the vehicle may cause misalignment. This could lead to failure of the repair.
NOTE: Always refer to the manufacturer's label directions for the type of repair materials, fillers and bonding agents being used as they are material specific.
NOTE: The following procedure applies to repair of structural cracks and large gouges. If damage is cosmetic, use of reinforcing cloth may not be necessary.
Panels to be repaired should be dry and at room temperature 18 C (64.4 F) to 24 C (75.2 F) prior to carrying out any repairs. Both sides of the panel must be thoroughly cleaned before sanding or grinding.
Repair
NOTE: Sheet-Molded Composite (SMC) Panel Repair
1. Cover the break in the Sheet-Molded Composite (SMC) (front and back) with masking tape. This protects the damaged area from absorbing the prep cleaner and eliminates wicking of the cleaner through the fibers into the Sheet-Molded Composite (SMC).
2. Remove all waxes, silicones, dirt and road oils from the area surrounding both sides of the damaged area with a plastics wax and grease remover.
3. Remove the tape and sand the back of the repair area with an angle grinder, Dual Action (D/A) sander or by hand using 80-grit sandpaper. Remove all dust with a vacuum and tack cloth. Use Special Service Tool: ALCV-200.
4. Create a reinforcing patch using a piece of scrap Sheet-Molded Composite (SMC) that conforms well to the back of the damaged area or form a patch from fiberglass cloth.
5. Cut a section of cloth large enough to cover the repair, plus around the repair area. Cut a section of plastic film backing approximately larger than the cloth. Lay the plastic on a smooth, flat surface where it will be used to create a pyramid patch.
6. Follow manufacturer's directions and apply adhesive to the plastic film backing and smooth with plastic spreader to recommended thickness. Place the pre-cut fiberglass cloth on the adhesive-coated plastic film. Cover the cloth with a coat of repair adhesive and spread to the recommended thickness. Material : Plastic Bonding Adhesive / TA-9
7. Apply the prepared patch to the backside of the panel and compress. Follow manufacturer's instructions for adhesive cure. Remove plastic film after adhesive cures and sand as necessary to remove roughness.
8. Remove masking tape from the front side of damaged area and grind down to the backing patch. Use an angle grinder with a 30 to 40-grit wheel. Make a gradual taper in the area, this will prevent bull's-eyes or read-through in the finished repair. Sand prepared area with a Dual Action (D/A) sander or hand-sand with 80-grit sandpaper. Use Special Service Tool: ALCV-200.
9. Build a pyramid patch using fiberglass cloth or equivalent and adhesive. Following manufacturer's directions, apply patch to damaged area. Material : Plastic Bonding Adhesive / TA-9
10. Rough-grind area to remove excess adhesive. Sand repair area with 80-grit sandpaper, making sure to cut slightly below the Sheet-Molded Composite (SMC) finished surface. This will allow for a finish coat of plastic repair filler material.
11. Apply a finish coat of plastic repair filler material per manufacturer's directions.
2016 Mustang workshop publication supplied to Mustang Atlas. Original technical text and illustrations; HTML formatting by Mustang Atlas. Source page numbering is retained for traceability. Follow the configuration, revision, warnings, and cross-references in the material. About this edition.