Aluminum Body Parts - Use of Plastic Filling Compounds
84porsche01Subject
Aluminum Body Parts
Part Identifier N/A
Applies To 928
928S
All Years
Group
50
Key Points
Use of plastic filling compounds for body repairs
Number
84 - 01
April 18, 1984 C
To ensure highest quality finish and durability when repairing aluminum body parts, Porsche recommends the following plastic filling compounds and application methods:
Work sequence
-clean aluminum surface
- apply epoxy thick coat filler F90
- let dry and grind smooth
- apply coat of polyester filler
- let dry and grind smooth
- prime coat with reaction primer R 48
OR
- roughen metal surface with 120 grit sandpaper
- coat with polyester filler
- let dry and grind smooth
- prime coat with reaction primer R 48
Note
See attached charts for information on plastic filler applications and physical properties.
Epoxy thick coat filler F 90 P/N 999.915.330.40
Use epoxy thick coat filler F 90 when filling coat is applied on steel, aluminum, glass fiber reinforced polyester, and where high adhesion is required.
Epoxy thick coat filler grinds off easily, resists rust and holds paint well.
Surfaces to be coated must be free of rust, dry, and grease-free.
Galvanized sheet metal must be coated with chrome acid to inhibit corrosion.
Warning
Always wear air mask with fresh air feed when using this material.
Polyester filler
ALN. 787.003.10 Two component polyester filler (1 kg) ALN. 787.003.20 Two component polyester filler (2 kg) ALZ 018.000.02 Hardener (40g)
Warning
Always wear air mask with fresh air feed when using this material
Use polyester filler on large area irregularities (dents, deep scratches) in body sheet metal.
Note
Mix polyester filler with hardener in a ratio of 2 to 3% by weight. (1 g hardener = 3 cm from tube)
Caution
If too much hardener is used, filled area may bleed through final paint coat.
Reaction primer R 48 P/N 911. 096. 162. 04
R 48 is a two component primer that resists corrosion, adheres to irregular surfaces, has an insulating effect on plastic and fills easily.
Use R 48 on steel, iron, aluminum, spray cast zinc, galvanized sheet metals, copper and brass.
All air and oven drying enamels (up to 201.0~F) can be applied to R 48
Do not apply polyester and other two component products to R 48.
Warning
Always wear air mask with fresh air feed when using this material