Body Repair ManualKalos RUST PREVENTION

RUST PREVENTION

ZINC TREATED STEEL PLATE REPAIR

Avoid puttying as much as possible when repairing a newcar. Use alternative methods as much as possible.

CAUTION

Most paints contain substances that are harmfulif inhaled or swallowed. Read the paint labelbefore opening the container. Spray paint only ina well ventilated area.
Cover spilled paint with sand, or wipe it up atonce.
Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. Avoidcontact with skin.
If paint gets in your mouth or on your skin, rinseor wash thoroughly with water. If paint gets in youreyes, flush with water and get prompt medical attention.
Paint is flammable. Store it in a safe place, andkeep it away from sparks, flames or cigarettes.

Operation	Tools/Materials	Procedure	Remarks
1. Prep the repairarea.	Double-action sander,#80 sandpaper.	Sand the area with a double-actionsander and #80 sandpaper.Clean with wax and grease remover.	.
2. Apply putty Note : Putty canbe applied afterpriming as described in step 4.	Epoxy-based putty. Mix the putty and hardeneraccording to the manufacturer's direcctions. Polyester resin putty.Body filler.	Apply in several thin coats if necessary. Try to avoid leaving pinholes inthe putty. Follow the manufacturer's recommendations for preparaton.	.
3. Sand and clean theputtied area.	Double-action sander, orbitalsander, hand sanding file, #80,#120, #240 sandpaper, wax andgrease remover, shop towels.	Rough-sand the area with a double-action sander and #80 sandpaper,then sand with #120 sandpaper.Featheredge with #240 sandpaper.Clean with wax and grease remover.	.
4. Coat with primer. Note : Apply tobare sheet metaland puttied area.	Epoxy-based primer and hardener, epoxy thinner. Mix and thin the primeraccording to themanufacturer's directions.	Apply 2-4 coats, allowing sufficientflash time between coats. Force dry at 60-70∞C(140-158∞F) forat least 30 minutes.	Spray to athickness of30-35microns.
5. Sand and clean thewhole area.	Double-action sander, #400sandpaper, wax and greasesremover, shop towels.	Sand the whole area to be repaintedwith a double-action sander and #400sandpaper. Blow off with compressed air. Cleanwith wax and grease remover.	.
6. Coat the wholearea to be repainted with primer/surfacer.	Polyester/urethane resin primer/surfacer. Mix and thin the primeraccording to themanufacturer's directions.	Apply 2-4 coats, allowing sufficientflash time between coats. Force dry at 60-70∞C(140-158∞F) forat least 30 minutes.	Spray to athickness of30-35microns.
7. Sand and clean thewhole area to berepainted.	Hand sanding file, double-actionsander, #240, #320, #400, #600sandpaper, wax grease andremover, shop towels.	Sand the repair area by hand with#240 sandpaper until it's level. Sandthe whole area to repainted with #320-600 sandpaper. Clean with wax and grease remover.	.
8. Top-coat the wholearea to repainted.	Acrylic urethane resin top coatpaint, hardener, and thinner. Mix and thin the paint according to the manufacturer'sdirections.	Apply 2-4 coats, allowing sufficientflash time between coats. Force dry at 60-70∞C(140-158∞F) forat least 30 minutes.	Spray to athickness of40-50microns.

RUST PREVENTIVE PROCEDURE

GENERAL INFORMATION

Corrosion starts immediately after the steel base contacts the atmosphere. The condition is aggravated bysea wind, road salt, rain, snow and industrial fallout.There are many ways to protect automobiles againstcorrosion. Primers, primer surfacers and paints areapplied by electrodeposition or spray to protect the carbody.

Anti-rust Agents and Spray Guns

Use the following anti-rust agents or equivalents whenmaking a body repair.

Caution : ANTI-RUST agents contain substancesthat are harmful if you breathe or swallow them, orget them on your skin. Wear converalls, gloves, eyeprotection, and an approved respirator while usingsuch agents.

Anti-rust agents:

RUSTOP DEOX #100 WAXOYL	U.S.A. MARKET AUTO ARMOR 1031 (made by E.C.P)	To be applied to welded joints inside body panels.
NOX-RUST 409-20S SOLTION 1000S	AUTO ARMOR OUTSIDE COATING (made by E.C.P)	To be appled to under floor and wheelhouse.

Spray guns:

Use the correct gun for the agent being used.

Use of a pressure type spray gun is recommendedwhen work involves a considerable number of cars.

For RUSTOP	DEOX#100	For WAXOYL	For NOXRUST 409-20S/SOLTION 1000S

Protectors: Wear gloves, mask and suitable eye protection. Use light oil and a rag to clean up spilled anti-rust agents.

Precautions:

Before applying an anti-rust agent, thoroughly cleanthe areas to be coated with a steam cleaner, etc.,and let dry.
Note : Waxoyl may be applied to wet surface.
Spray an anti-rust agent sufficiently until the excessamount oozes out when filling, the doors, etc.Wipe the excess agent with a clean rag dampenedwith light oil.
Do not spray an anti-rust agent to the brake hoses,brake wheel cylinders, brake drums, exhaust muffler and its related parts, emission control devices inthe engine compartment, ball joint covers, etc.Wipe up spilled agent at once.
Heat an anti-rust agent to room temperature[36.5∞C(97.7∞F)] by submerging the container in hot waterwhen outside temperature is below 10∞C(50∞F).
Ventilate when spraying an anti-rust agent since itcontains a small amount of organic solvent. Keepsparks, flames and cigarettes away.

Caution : The remaining agent will harden in thepassages of the spray gun, making them unserviceable.

AREA COVERED BY ANTI-RUST AGENTS

Note :

Coating thickness : 0.05mm (0.002 in).
Hatching indicates anit-rust agent coating areas.
Follow the below figure for paint repair or refinishing.

Cavity Wax
Wheelhouse Inner Patch
Hole for cavity wax injection
Side Outer Panel
Door Outer Panel
Door Inner Panel
Floor Side Panel
Side Inner panel

Underbody Wax
Rear Mud Guard
Rear Wheel Guard
Front Mud Guard
Fender Liner

UNDERCOATING DIAGRAM

Note :

Coating thickness : MIN 0.5mm (0.020 in).
Hatching indicates anit-rust agent coating areas.
Follow the below figure for paint repair or refinishing.
Do not apply the part mounting areas and holes.

Undercoater
All studs to be free of undercoater
Towing eye to be free of undercoater

Undercoater
Fender
Apron Outer Panel
Shock Tower Reinforcement
Apron Inner Panel
Front Longitudinal
Mounting surface to be free of undercoater
Side Outer Panel
Floor Panel
Side Inner Panel
Floor Side Panel
Rear Shock Absorber Reinforcement
Wheelhouse Inner
Rear Longitudinal Patch
Rear Longitudinal Center Patch
Rear Floor Panel
Rear Longitudinal
Towing eye to be free of undercoater
Front Floor Panel
Wheel carrier rear support to be free of undercoater
Dash Panel

Undercoater
Wheelhouse Inner Panel
For ABS wheel harness
For seat belt
Side Outer Panel
Wheelhouse Inner Patch
Heatshield fixing studs to be free of undercoater 4 places
Heatshield fixing studs to be free of undercoater 5 places
Rear Muffler heatshield fixing studs to be free of undercoater 4 places
Towing eye to be free of undercoater
Trailing arm reinforcement attachment area to be free of undercoater 2 places
Brake and fuel lines fixing studs to be free of undercoater 4 places
Front suspension cross member fixing area to be free of undercoater 4 places
All holes for assembly to be free of undercoater