Audi A8 D5 - Bonded Joints with Aluminium; Processing Metal and Aluminium Filler

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9.3 Bonded joints with aluminium
WARNING
Pre-treatment applies to old flange only.
– Remove remnants of adhesive, paint, wax, etc.
– Sand bonding surface down to bare metal using a clean sand‐
ing disc (grit size P 80 or P 100).
– Use clean brush to remove sanding dust.
– Clean bonding surfaces with cleaning solution - D 009 401
04- .
– Treat flanges with silicate stone - DA.009.800 - and holder -
V.A.G 1931- .
– Apply a thin coat of aluminium primer - DA 009 801 - using
applicator - D 009 500 25 - and allow to flash off.
A silicate adhesive layer is formed which ensures long-term du‐
rability of the bonded joint. The surface becomes matt.
Do NOT use solvents.
WARNING
Mask bonding surfaces when painting inner sides.
Parts must be joined and secured in position within 30 minutes
as otherwise the formation of a surface skin will result in inade‐
quate adhesion at the flanges.
– Fit rivets and wipe off emerging adhesive.
At temperatures up to 20° C, rivets must be fitted within 90 mi‐
nutes and at temperatures above 20° C within 40 minutes starting
from application of adhesive.
Note
♦ For large parts, e.g. roof, the assistance of a second person
is required, as otherwise the adhesive will dry before work is
completed.
♦ In the event of interruptions lasting up to 30 minutes, press out
and discard an approx. 100 mm long bead to ensure that new
material is properly mixed. In the event of interruptions lasting
longer than 30 minutes, replace mixing nozzle and press out
a 100 mm long bead. If several cartridges are required for re‐
pair work, the same mixing nozzle can be used.
9.4 Processing metal and aluminium filler
Processing metal and aluminium filler has numerous benefits:
♦ Very good adhesive properties on bare surfaces
♦ Thicker layers possible than with polyester filler
♦ If work is performed correctly, less tendency to shrink subse‐
quently or sag
♦ Can also be used around adhesive bonds as it does not build
up much heat
General InformationBody Repairs, General Body Repairs - Edition 04.2018
9. Surface repairs 53