G E N E R A L C A R E
SHALLOW SURFACE SCRATCHES
Remove the scratches by lightly hand wet sanding
the surface with 600 grit sandpaper. Sand in one
direction only and only until the scratches are
removed (to retain as much thickness as possi-
ble). This will create a dull surface. To improve the
surface gloss, sand the area with 1000 grit,
then 1500 grit sandpaper. The surface should be
starting to recover some of the gloss. To further
increase the gloss level, polish the area with ultra
fine polish (automotive polishes suitable for clear-
coat).
MINOR DAMAGE
Minor damage is defined as a problem that does
not affect the overall structure of the part or area.
They are usually appearance concerns, such as
scratches, surface mars, and minor dents. It is
very important to ascertain the full extent of the
damaged area. If any jagged edges or cracks are
present, see the major damage section.
Mask off the damaged area, lightly hand sand
(220 grit) the damaged area to remove any sur-
face ridges and to promote adhesion. Sand in
one direction only. In a well-ventilated area, apply
a thin layer of Plexus adhesive in a 1:1 ratio to the
damaged area. After the Plexus has dried, smooth
the area with a fine (220 grit) sandpaper. Now,
apply a thin layer of automotive body filler (Bondo)
to fill in any imperfections, and allow to dry. Lightly
sand with a 220 grit sandpaper, followed by a 400
grit sandpaper, then a 600 grit sandpaper. Finally,
apply an automotive paint to match the color.
MAJOR DAMAGE
This type of damage can be holes, cracks, or large
dents. Cracks, even those found around holes,
must be prevented from growing. To do this, the
ends must be found and blunted (by drilling small
holes). Once this is done, the crack can be ground
or routed into a V groove. This allows it to be filled
easily and promotes a good bond. We suggest
using a Dremel tool, being sure to work in a well-
ventilated area.
Mask off the damaged area and lay down a bead
of Plexus adhesive in a 1:1 ratio into the dam-
aged area, slightly under filling the V groove. The
Safety C
Use of solvents requires adequate ventilation,
keeping in mind that they are usually highly
flammable. Use proper procedures to avoid
injury. In some instances, the use of these
materials is controlled. Check all regulations prior
to using.
Keep in mind that a repair can only attempt to
match the performance predicted in the original
part. The repair may not be quite as strong or stiff
as the original part. The overall part/system be-
havior has probably changed.
Plexus will expand as it hardens. Skim the excess
Plexus (if any) from the repair area keeping it level
with the surrounding area. Allow to dry for 1 hour.
Sand the damaged area until the surface is flush
with the surrounding area. Apply a thin layer of
automotive body filler to fill any voids. Allow the
filler to dry, then wet sand with 220, 400, then 600
grit sandpaper.
After sanding the repaired area flush to the sur-
rounding area, paint can then be applied. Recom-
mended paints are spray enamels and oil based
enamel brush-ons (Rustoleum).
Always follow all warnings and instructions given
by the manufacturers of the products used for re-
pairs.
This information is provided for your guidance
only. We urge you to make all tests you deem ap-
propriate prior to use. No warranties, either ex-
pressed or implied, including warranties or mer-
chantability or fitness for a particular purpose, are
made regarding products described or information
set forth, or that such products or information may
be used without infringing patents of others.
P A G E 8
onsiderations:
