Repair Instructions For Laminated Safety Glass

51 31 ... Repair Instructions For Laminated Safety Glass

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






Brush 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 fragments in impact spot from the outside using a scribe so that a rough surface is produced.

Important! 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 with aperture (5) of sputnik head (6) located precisely over impact point (2).






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






Screw in knurled head screw (7) until sputnik head feet (8) just bear firmly on windscreen.

Important! Do not screw in too firmly - this may cause tension and start breaking the windscreen.






Screw cylinder (9) so far into sputnik head (6) that rubber seal (10) firmly surrounds impact spot (2) on the windscreen and the sputnik head feet (8) just start lifting slightly.

Important! Do not screw in too firmly - this may cause tension and start breaking the windscreen.






Unscrew injector (11) from cylinder (9), look into top of cylinder (9) and check whether rubber seal (10) is centrally located over impact spot (2).
Correct the position if necessary.






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

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

Note: There will be approx. 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).
Dimension (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 removed, heat the windscreen from the inside when pressing for several seconds using a cigarette lighter.

Important! Do not apply heat for too long - this may cause tension and cause the windscreen to jump. Hold the flame as close as possible to the glass, but without contact.






Loosen knurled screw (7), swing sputnik head (6) aside and look at repair area 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 head (6) back over the impact spot and screw in knurled screw (7) as far as before. Repeat steps starting with pressure/vacuum alternation.







Swing arresting lever forwards and remove tool holder from windscreen.







Let one drop of resin drip onto the impact spot and cover with transparent foil.

Note: Only lay transparent foil on impact spot loosely. Do not press it on!






Apply ultraviolet lamp over repair area 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 transparent foil and scrape off excessive resin with a razor blade.






Let another drop of resin drip onto the impact spot and cover with a new piece of transparent foil.






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






Apply ultraviolet lamp over repair area again 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 transparent foil and scrape off excessive resin all around the impact spot with razor blade.

Important! Do not scrape on impact spot!






Polish repair area with a cloth (that does not lose lint) until surface is clean and smooth.