Repair Instructions For Composite Safety Glass

51 31 ... Repair Instructions For Composite Safety Glass

Note: Heat vehicle to room temperature ( > 20° C ), if necessary, heating windshield from inside.






Brush in suction cup (1) of hollow mirror with thin coat of gel and position suction cup on inside of windscreen in such a way that the impact spot (2) can be observed from the outside in hollow mirror (3).






Remove all glass splitters in impact spot from the outside using a scribe so that a rough surface is produced.

Caution! Do not increase the size of the impact spot hole.






Brush in suction cup of tool holder with thin coat of gel.






Position tool holder (4) on outside of windscreen in such a manner that opening (5) in sputnik head (6) is precisely over impact spot (2).






First unscrew knurled screw (7). Move arresting lever forwards, then backwards (suction unit fixed).






Tighten knurled screw (7) until feet on sputnik head (8) are upright on windshield (do not tighten down too hard - this can create tension, causing windshield to jump out).






Screw cylinder (9) into sputnik head (6) until rubber gasket (10) firmly encloses locating point (2) on windshield and sputnik heads (8) once again lift up slightly (do not tighten down too hard since this can create tension, causing windshield to jump out).






Screw injector (11) out of cylinder (9), look into cylinder (9) from above and check whether rubber seal (10) is centered around impact spot (2).
Correct the position if necessary.






Open bottle of resin and pour about one third of its contents into the cylinder.

Caution! Close bottle of resin again after using and protect it against ultraviolet light.






Mix poured in resin with a wooden stick to remove any air bubbles.






Screw injector (11) down to dimension (A) in cylinder (slight resistance encountered) and leave everything like this for approx. 5 minutes.
Distance (A) = 5 mm

Note: There will be about 16 bar pressure in this position. When observing the impact spot, it will be noticed that air slowly disappears from the impact spot (recognized as black shadow).






Unscrew injector (11) quickly as far as distance (B).
Distance (B) = 12 mm

Note: In this position vacuum will now "suck" the rest of the air out of the impact spot.






Screw in injector (11) into cylinder as far as distance (A) again (slight resistance will be noticed) and leave everything as it is for several minutes.
Distance (A) = 5 mm

Repeat this step, alternating between pressure and vacuum, several times and then leave injector (11) in an intermediate position between distance (A) and distance (B) for some time.

Note: If all air has still not been purged, heat windshield during pressure application process with lighter for a few seconds (not for too long - tension can build up, causing the windshield to jump out). Hold the flame as close as possible to the glass, but without contact.






Loosen knurled head screw (7), swing sputnik head (6) aside and look at repaired spot from above and in the hollow mirror from different angles of observation. There should no longer be visible air inclusions.
However, if air is still visible, swing sputnik (6) back over the impact spot and screw in knurled head screw (7) as far as before. Repeat steps starting with pressure/vacuum alternation.






Swing arresting lever forward and take tool holder off windscreen.






Let one drop of resin drip on the impact spot and cover with plastic sheet.

Note: Only lay plastic sheet on impact spot loosely. Do not press it on!






Apply ultraviolet lamp over repaired spot and press on firmly (press on suction cups separately).
Connect ultraviolet lamp and let resin harden for about 10 minutes.






Remove ultraviolet lamp, pull off plastic sheet and scrape off excessive resin with razor blade.





Let another drop of resin drip on the impact spot and cover with a piece of new plastic sheet.






Run over the plastic sheet carefully with a razor blade so that excessive resin runs out on the sides.






Position ultraviolet lamp over repaired spot and press on firmly (press on suction cups separately).
Connect ultraviolet lamp and let resin harden for about 10 minutes.






Remove ultraviolet lamp, pull off plastic sheet and scrape off excessive resin all around the impact spot with razor blade.

Caution! Do not scrape on impact spot!






Polish repaired spot with a cloth (that does not lose lint) and polish until surface is clean and smooth.