Refinishing Procedures
Refinishing Procedures1. Featheredging (polishing damaged areas)
1. Damage to aluminum alloy base
- Sand the damaged area flat and smooth with a double action sander and #60 or #80 disc paper.
- Sand the boundary between the metal surface and undercoat with a double action sander and #180 or #280 disc paper. Try to sand a larger area than the damage.
NOTE:
- Make sure there is not height difference between the metal surface and undercoat.
- If double action sander is not available, use a rubber block and wrap sandpaper around it to sand the surface.
WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.
2. Damage to Undercoat
Intermediate coat 1
Intermediate coat 2
Top coat
Paint coat on replacement parts
Sand the damaged surface flat and smooth with a double action sander and #280 or #320 paper.
NOTE:
- If double action sander is not available, use a rubber pad and wet or dry sand the surface with #280, #320, #400 or #600 sandpaper.
- After sanding, check that the surface is flat and smooth.
- Perform the operations in Item 1-1 above for the areas where parts are welded to the body.
2. Preparation of aluminum alloy base surface
Remove all corrosion from the damaged area using #180 or #280 paper.
3. Air Blowing/Degreasing
Air blow the sanded area, then degrease with a wax and grease remover (for USA usage-DuPont 38125 Enamel Reducer).
WARNING:
- Do not use high air pressure: use only an approved, 210 kPa (2.1 kg/sq.cm, 30 psi) air nozzle.
- Wear goggles or safety glasses to prevent eye injury.
4. Treatment of aluminum alloy base
- Brush or spray a solution of chrome phosphate or washer primer to the exposed aluminum alloy base.
- Use the following materials to treat the aluminum alloy base:
- KAR washer primer (Kansai Paint) (for usage- DuPont)
- 110 active primer Agent (Nippon Paint)
- G113 treatment (Isam Paint) (for USA usage- DuPont)
NOTE:
- Follow the manufacturer's instructions.
- Treat the aluminum alloy base surface, as much as possible, to provide a better bonding surface for the subsequent paint.
5. Application of Filler
Drying
Sanding
- Small cracks or pinholes in the aluminum alloy base should be repaired with a filler and sanded flat and smooth.
NOTE:
- Mix the filler to the hardener in the correct ratio.
- Follow the filler manufacturer's instructions.
WARNING: Body parts being dried with an industrial dryer can get hot enough to cause injury. Do not touch parts being dried.
- Allow the filler to air dry for about 5-6 minutes, then force dry with an infrared lamp.
NOTE: Keep a 40-50 cm (16-20 in) from the filler while drying.
- Stop drying the filler if a white mark appears when the surface is scratched with your nail. Wet or dry sand the surface flat and smooth with a #280 or # 320 paper.
6. Air Blowing/Degreasing
Air blow the surface to be repaired, then degrease with a wax and grease remover (for USA usage-DuPont 38125 Enamel Reducer).
NOTE: Also clean and degrease the surfaces where masking tape will be attached.
7. Masking
Mask the areas surrounding the damage to prevent overspray from the primer surfacer.
NOTE: Use masking tape and paper to cover the undamaged areas.
8. Application of Undercoating (Primer Surfacer)/ Drying
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
- Spray the primer surfacer over the filler and surface (use epoxy or urethane 2-part primer surfacer).
Spray : 2-3 coats.
- Use the following materials:
615S Primer Surfacer (DuPont)
Primer Surfacer EP (Akzo)
NPS735 Urethane Primer Surfacer (R-M)
- Let the primer surfacer air dry for 5-10 minutes, then force dry with a infrared lamp.
NOTE: Keep the dryer 40-50 cm (16-20 in) from the surface.
9. Application of Polishing Undercoat
- Remove the masking paper and tape.
- Check that the undercoat is dried thoroughly, then dry or wet sand the surface with a #280 or #320 paper.
NOTE:
- Use a rubber block and sand flat and smooth.
- Sand the entire surface to be refinished.
10. Air Blowing/Degreasing
WARNING:
- Do not use high air pressure: use only an approved, 210 kPa (2.1 kg/sq.cm, 30 psi) air nozzle.
- Wear goggles or safety glasses to prevent eye injury.
Air blow all the surfaces, then degrease with a wax and grease remover (for USA usage-DuPont 38125 Enamel Reducer).
NOTE: Also degrease the surfaces where masking tape will be attached.
11. Masking
Mask the undamaged areas surrounding the damage to prevent overspraying of primer surfacer (intermediate coat).
NOTE: Use masking tape and paper to mask the body. A vinyl cover may also be used to effectively mask the body.
12. Application of Intermediate Coat 1 (Primer surfacer-is used for this purpose) spraying/drying
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
- Spray either 2-part epoxy or urethane primer surfacer to polished primed surface as intermediate coat.
- Let the paint coat air dry for 5-10 minutes, then force dry with an infrared lamp.
NOTE: Keep the dryer 40-50 cm (16-20 in) from the surface.
For replacement parts:
Spray intermediate coat 2 on over the surface.
NOTE:
- For the back faces, you may start with Step 16 "Application of Intermediate Coat 2."
- Top coat enamel is used for this purpose
13. Polishing of Intermediate Coat 1
Check that the undercoat is dried thoroughly, then dry or wet sand the surface with a #400 or #600 paper.
NOTE: Use a rubber block and sand flat and smooth, covering entire surface.
14. Air Blowing/Degreasing
WARNING:
- Do not use high air pressure; use only an approved, 210kPa (2.1 kg/sq.cm, 30 psi) air nozzle.
- Wear goggles or safety glasses to prevent eye injury.
Air blow all the surface, then degrease with a wax and grease remover (for USA usage-DuPont 38125 Enamel Reducer).
15. Masking
Check the masking paper (Step 11) for tears or fouling, and repair or reinforce as necessary.
16. Application of Intermediate Coat 2 (same color as enamel) top coat spraying/drying
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
- Use the same color paint as the top coat, and spray it over the surface until the intermediate coat (primer surfacer) is fully covered.
- Spray the paint slightly thicker than normal to allow for loss during subsequent polishing.
- Super ponacle II (R-M)
- Super Centari (Du Pont)
- Auto cryl (Akzo)
17. Polishing of Intermediate Coat 2
- Check that the paint coat has been dried thoroughly, then dry or wet sand the surface with a #600, #800, or #1000 paper.
NOTE: Use a rubber block and sand flat and smooth, being careful not to expose the intermediate coat 1.
Polishing of Top Coat (if damaged):
- Use the same technique described above.
WARNING:
- Do not use high air pressure; use only an approved, 210kPa (2.1 kg/sq.cm, 30 psi) air nozzle.
- Wear goggles or safety glasses to prevent eye injury.
18. Air Blowing/Degreasing
- Air blow the entire surface, then degrease with a wax and grease remover (for USA usage-DuPont 38125 Enamel Reducer).
- For shading or spot painting, polish the area with a polishing compound. Sand with a #2000 paper to give a better bonding surface for the subsequent paint.
19. Masking
- Remove all existing masking papers, then mask with new papers.
- Use a heat resistant type masking tape (SCOTCH TAPE) where tape is attached directly to the body.
- Use brown paper or masking roll paper to cover.
NOTE:
- Mask the area surrounding the damage sufficiently to prevent overspray. It is also a good practice to use a vinyl cover to protect other areas.
- Protect resin parts with aluminum foil under the brown paper or masking paper to prevent damage to due to heat during baking.
20. Application of Top Coat Spraying/drying
NOTE: Black painting of roof panel.
- Prior to putting the car in the painting booth, thoroughly clean the interior and spray water over the floor. Be careful about air-blow dust and dirt.
WARNING:
- Do not use high air pressure; use only an approved, 210kPa (2.1 kg/sq.cm, 30 psi) air nozzle.
- Wear goggles or safety glasses to prevent eye injury.
- Air dry and degrease the surface before spraying the paint. Also clean the surface with a tack cloth.
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
- Spray color matched top coat over the prepared surface. Apply 2-3 coats in two directions until the intermediate coat 2 is fully covered.
NOTE: For application of the top coat, refer to Step 16 "Application of Intermediate Coat 2."
Solid color: Color enamel + color clear coat
Metallic color: Metallic enamel + clear coat
Pearl color: Pearl enamel + clear coat
WARNING: Body parts being dried with an industrial dryer can get hot enough to cause injury. Do no touch parts being dried.
- After spraying, allow the paint to settle for about 10 minutes, then force dry with an infrared lamp.
NOTE: Follow the paint manufacturer's instructions.
21. Polishing/buffing
- Let the paint dry gradually, then polish the surface carefully using a polishing compound and sponge buff.
- To remove lint or dirt, wet sand the surface with #2000 paper or finer first, then polish with compound.
NOTE: Polish all roughness caused by sanding thoroughly. To do this, first polish with very fine compound, then with ultra fine compound.
- After polishing, remove the masking paper and tape and wash the entire vehicle thoroughly.