01/12/2014 BodyRepairManualCaptivaRUSTPREVENTION

Captiva

RUSTPREVENTION
ZINCTREATEDSTEELPLATEREPAIR
Avoidputtyingasmuchaspossiblewhenrepairinganewcar.Usealternativemethodsasmuchaspossible.
CAUTION

Mostpaintscontainsubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabelbeforeopeningthecontainer.Spraypaintonlyinawellventilatedarea.
Coverspilledpaintwithsand,orwipeitupatonce.
Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.Avoidcontactwithskin.
Ifpaintgetsinyourmouthoronyourskin,rinseorwashthoroughlywithwater.Ifpaintgetsinyoureyes,flushwithwaterandgetpromptmedicalattention.
Paintisflammable.Storeitinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.

Operation Tools/Materials Procedure Remarks

1.Preptherepairarea.
2.Applyputty
Note:Puttycanbeapplied
afterprimingasdescribedinstep
4.
Doubleactionsander,#80sandpaper.
Epoxybasedputty.
Mixtheputtyand
hardeneraccordingtothe
manufacturer'sdirecctions.
Polyesterresinputty.Body
filler.
Sandtheareawithadoubleactionsanderand#80sandpaper.Clean .
withwaxandgreaseremover.
Applyinseveralthincoatsifnecessary.Trytoavoid .
leavingpinholesintheputty.
Followthemanufacturer'srecommendationsfor
preparaton.

3.Sandandcleantheputtiedarea. Doubleactionsander,orbitalsander,handsanding Roughsandtheareawithadoubleactionsanderand#80 .

file,#80,#120,#240sandpaper,waxandgrease sandpaper,thensandwith#120sandpaper.Featheredgewith#240
remover,shoptowels. sandpaper.Cleanwithwaxandgreaseremover.
4.Coatwithprimer. Epoxybasedprimerandhardener,epoxy Apply24coats,allowingsufficientflashtimebetweencoats. Sprayto
thinner. Forcedryat6070C(140158F)foratleast30minutes. athicknessof30
Note:Applytobaresheet Mixandthinthe 35microns.
metalandputtiedarea. primeraccordingto
themanufacturer'sdirections.

5.Sandandcleanthewholearea. Doubleactionsander,#400sandpaper,waxand Sandthewholeareatoberepaintedwithadoubleactionsanderand .

greasesremover,shoptowels. #400sandpaper.
Blowoffwithcompressedair.Cleanwithwaxandgreaseremover.
6.Coatthewholeareatobe Polyester/urethaneresinprimer/surfacer. Apply24coats,allowingsufficientflashtimebetweencoats. Sprayto
repaintedwithprimer/surfacer. Mixandthinthe Forcedryat6070C(140158F)foratleast30minutes. athicknessof30
primeraccordingto 35microns.
themanufacturer'sdirections.

7.Sandandcleanthewholeareato Handsandingfile,doubleactionsander,#240,#320, Sandtherepairareabyhandwith#240sandpaperuntilit'slevel. .

berepainted. #400,#600sandpaper,waxgreaseandremover,shop Sandthewholeareatorepaintedwith#320600sandpaper.
towels. Cleanwithwaxandgreaseremover.
8.Topcoatthewholeareato Acrylicurethaneresintopcoatpaint, Apply24coats,allowingsufficientflashtimebetweencoats. Sprayto
repainted. hardener,andthinner. Forcedryat6070C(140158F)foratleast30minutes. athicknessof40
Mixandthinthepaint 50microns.
accordingtothe
manufacturer'sdirections.

RUSTPREVENTIVEPROCEDURE
GENERALINFORMATION
Corrosionstartsimmediatelyafterthesteelbasecontactstheatmosphere.Theconditionisaggravatedbyseawind,roadsalt,rain,snowandindustrialfallout.Thereare
manywaystoprotectautomobilesagainstcorrosion.Primers,primersurfacersandpaintsareappliedbyelectrodepositionorspraytoprotectthecarbody.
AntirustAgentsandSprayGuns
Usethefollowingantirustagentsorequivalentswhenmakingabodyrepair.

Caution:ANTIRUSTagentscontainsubstancesthatareharmfulifyoubreatheorswallowthem,orgetthemonyourskin.Wearconveralls,gloves,
eyeprotection,andanapprovedrespiratorwhileusingsuchagents.

Antirustagents:
RUSTOP U.S.A.MARKET
Tobeappliedtoweldedjoints
DEOX#100 AUTOARMOR1031
insidebodypanels.
WAXOYL (madebyE.C.P)
NOXRUST40920S AUTOARMOROUTSIDECOATING Tobeappledtounderfloor
SOLTION1000S (madebyE.C.P) andwheelhouse.
Sprayguns:
Usethecorrectgunfortheagentbeingused.
Useofapressuretypespraygunisrecommendedwhenworkinvolvesaconsiderablenumberofcars.
ForRUSTOP DEOX#100 ForWAXOYL ForNOXRUST409

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01/12/2014 BodyRepairManualCaptivaRUSTPREVENTION

Protectors:Weargloves,maskandsuitableeyeprotection.
Uselightoilandaragtocleanupspilledantirustagents.
Precautions:
1. Beforeapplyinganantirustagent,thoroughlycleantheareastobecoatedwithasteamcleaner,etc.,andletdry.

2. Note:Waxoylmaybeappliedtowetsurface.
3.
4. Sprayanantirustagentsufficientlyuntiltheexcessamountoozesoutwhenfilling,thedoors,etc.Wipetheexcessagentwithacleanragdampenedwithlight
oil.
5.
6. Donotsprayanantirustagenttothebrakehoses,brakewheelcylinders,brakedrums,exhaustmuffleranditsrelatedparts,emissioncontroldevicesinthe
enginecompartment,balljointcovers,etc.Wipeupspilledagentatonce.
7.
8. Heatanantirustagenttoroomtemperature[36.5C(97.7F)]bysubmergingthecontainerinhotwaterwhenoutsidetemperatureisbelow10C(50F).
9.
10. Ventilatewhensprayinganantirustagentsinceitcontainsasmallamountoforganicsolvent.Keepsparks,flamesandcigarettesaway.

Caution:Theremainingagentwillhardeninthepassagesofthespraygun,makingthemunserviceable.

AREACOVEREDBYANTIRUSTAGENTS
Note:
Coatingthickness:0.05mm(0.002in).
Hatchingindicatesanitrustagentcoatingareas.
Followthebelowfigureforpaintrepairorrefinishing.

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01/12/2014 BodyRepairManualCaptivaRUSTPREVENTION

1. FrontSideDoorOuterPanel
2. RockerInnerPanelCenterBrace
3. RockerInnerPanel
4. FloorPanel
5. BodySideOuterPanel
6. Waterdrainholestobefreeofwax3placesbothdoors.
7. SideDoorInnerPanel
8. C.Typicalsectionthroughbothdoors.

1. Thecatalyticconverter(ordieselparticulatefilterbox)andtheoxygensensoraretobeabsolutelyfreeofwax.
2. Allsurfacesorunderbodytobecoated.

UNDERCOATINGDIAGRAM

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01/12/2014 BodyRepairManualCaptivaRUSTPREVENTION
Note:
Coatingthickness:MIN0.5mm(0.020in).
Hatchingindicatesanitrustagentcoatingareas.
Followthebelowfigureforpaintrepairorrefinishing.
Donotapplythepartmountingareasandholes.

1. RockerInnerPanel
2. FloorPanel
3. FrontCompartmentSideRailRearOuterReinforcement
4. FrontCompartmentInnerSideRearRail

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01/12/2014 BodyRepairManualCaptivaRUSTPREVENTION

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