The
aluminum panels on the body may be repaired if damaged. Filler putty can be
used for minor dents, scratches, scrapes etc. However, major damage to a panel
will require removal of at least part of the panel. Because the panels are secured
to the ribs with a polyurethane adhesive, separating and removing panels is
difficult. Any rivets used on the panels are easily removed by drilling off the
rivet head and, using a punch, drive out the rivet shaft. All windows, access
doors, vents, belt and roof line trim mouldings in the damaged area should be
removed before removing the panel. An air chisel will be helpful to remove the
panel. Operate the air chisel along the rib to break the adhesive bond between
the panel and the rib.
CAUTION: Be
careful during chiseling, sawing, drilling etc. on the aluminum panels not to damage
wiring, piping, insulation, components etc. which are located immediately
behind the panels. Any damaged rib will have to be straightened, replaced or
have shim material fastened to the rib so proper support will be provided for
the aluminum panel.
A replacement panel should be fitted after the ribs have been thoroughly cleaned of adhesive. A suggested method would be to grind off the adhesive with an extra coarse disc on an air driven grinding wheel. With the ribs cleaned a new panel may be fitted into the opening. Next, with the panel in place drill holes, or use existing holes, (at each corner and along the belt line and roof line) through the panel and rib for using pop-rivets. Remove panel and apply adhesive such as manufactured by Minnesota Mining and Manufacturing, 3539 A/B, or equivalent to the rib. This is a two part (base and accelerator) urethane adhesive designed for bonding aluminum, polyester, and steel. It is essential that the surface be thoroughly clean, dry, and grease free before application. Follow the manufacturers' mixing and curing instructions. Avoid repeated skin contact and use only in a well ventilated area. Position panel in place and pop-rivet using pre-drilled holes. The adhesive will cure at room temperature in 24 hours. The rivet holes may be ground off and the holes filled with a body putty.