12
© BTB Auto Glass & Body Shop Tools
2.2.12 Backfill Adhesive Removal (Bus & Train Glasses)
When the glass edge is surrounded by adhesive backfill, a
separation from the glass edge must be created prior to the cut out
procedure. The two options for removing backfill are outlined next.
Refer to
Diagram ZB
and
Diagram ZC
.
2.2.12.1 REMOVING BACKFILL USING A WK5-S BLADE
1. Fit a WK5-S or WK5 blade and WK11DW5 controller arm to the
power tool with flat side of blade facing controller arm wheel.
2. Apply the first cut with the flat side of the blade against the
glass edge operating at approximately 45°. The controller arm
wheel rolls along the glass to control the blade’s cutting depth.
3. To create the V cut, remove the blade from the tool, turn it over
and refit it. Flip the tool over so that the flat side of the blade still
faces the glass.
4. Apply a second V cut in the backfill to expose the glass edge,
again operating at approximately 45°. The controller arm wheel
rolls along the panel edge to control the blade’s cutting depth.
Refer to
Diagram ZB
below.
ADHESIVE
GLASS
GLASS EDGE
BUS OR
TRAIN
PANEL
FLAT SIDE OF WK5 or WK5S
BLADE MUST FACE GLASS
FOR 1st AND 2nd CUT
OPERATE AT 45° TO
GLASS FOR BOTH
1st AND 2nd CUT
WK11DW5
CONTROLLER ARM
1st cut
2nd cut
Diagram ZB
2.2.12.2 REMOVING BACKFILL USING A WK17 CHANNEL
BACKFILL BLADE
GLASS
WK26
Controller
Arm
Body panel
WK17
Blade
Adhesive
Glass
Glass
Adhesive backfill
being removed
Adhesive in
divisional joint
WK26
Controller
Arm
WK26
Use a rat tail (round) file to
sharpen radiused side
Diagram ZC
1. Always use a WK26 controller arm when using a WK17 channel
backfill blade to keep the power tool and blade parallel to the
glass surface and regulate cutting depth.
2. Blades must be kept very sharp. Use a small rat-tail file to
sharpen the radiused side of the blade.
3. The backfill blade is cut so that it will naturally dig in to create a
U-Shape cavity around the glass edges. Do not force or twist the
blade.
4. With the E-Tool, the backfill blade can be pushed or pulled along
the backfill.
2.3 Bonded Panel & Glass Roof Removal
2.3.1 Bonded Panel & Roof Module Frame Removal
Bonded panel removal and complete roof module removal
(including frame) are similar to glass removal in many ways. You
need to study & plan your removal technique:
• Choose whether to cut against the bonded panel or against the
vehicle frame.
• Select the appropriate blade that will place the flat side of the
blade toward the surface you want to cut against.
• Decide if a depth control arm is required.
•
Cut all easily accessible areas first.
• If space to enter a blade between the frame and panel is small
due to a thin layer of adhesive, use the tip of the blade and the
tool's reciprocal stroke to jab in and out to progressively cut the
adhesive.
• To reduce compression or pressure and allow faster cutting of
adhesive, progressively pull and flex the panel away, or insert a
lever/wedge or another blade to the adhesive area already cut.
Where bonded panel removal differs from glass removal:
• Panels are not subject to cracking/breaking
• Most panels can be flexed/peeled away as cutting progresses
• Panels are often lapped and bonded on top of another. Again,
this requires systematic and progressive separation as described
above.
Diagram ZD
Also refer to
Diagram A
on
page 2
.
2.3.2 Panoramic Glass Roof Removal (See also 2.3.1)
Panoramic glass roof is similar to glass removal in many ways:
• Refer to the
hints and
tips provided
throughout this
user manual.
• Removal of a
glass roof or
roof module
generally
require a
combination
of cutting from
inside vehicle and from the outside, leveraging and wedging to
reduce compression if needed. Use depth control arms where
required, and
NOTE
: Cutting lubrication is very important. Refer
to Section
2.1.5 Cutting Lubricant Is Important (Page 6).
• When cutting against softer material frames or panels (e.g.
aluminium, fibreglass, plastic), use of a double bevelled V (green)
or VR-S (blue) safety edge blade is recommended.
Diagram ZE
