NON-STRUCTURAL SHEET METAL REPAIR
Safety Notice
CAUTION: All Service and rebuilding instructions contained herein are applicable to, and for the
convenience of, the automotive repair industry only.
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures
recommended and described in this publication were developed for professional service personnel, and are effective
methods for performing vehicle repair. Following these procedures will help ensure efficient and economical vehicle
performance and service reliability. Some service procedures require the use of special tools designed for specific
procedures. These special tools should be used as recommended throughout this publication.
It is important to note this publication contains various Cautions and Warnings. These should be read carefully in
order to minimize risk of personal injury or the possibility that improper service may damage the vehicle or render
it unsafe. It is important to note that these cautions and warnings cover only the situations and procedures FCA US
LLC has encountered and recommended. FCA US LLC cannot possibly know, evaluate, and advise the service
trade of all conceivable ways in which service may be performed, or the possible hazards of each. Consequently,
FCA US LLC has not undertaken any broad service review. Accordingly, anyone that uses a service procedure
or tool that is not recommended in this publication must be certain that neither personal safety, nor vehicle safety
will be jeopardized by the service methods they select.
Safety Precautions
WARNING: Always wear an approved respirator, as well as skin and eye protection per adhesive
manufacturer recommendations as stated in the product Safety Data Sheets (SDS).
WARNING: There are necessary safety factors to follow when working with components made of
magnesium and components made of a combination of materials utilizing magnesium that
must be followed.
• Do not grind on the component. The grinding residue is highly combustible.
• In the event of a fire, a D-class rated fire extinguisher is necessary to extinguish.
• Do not expose the component to open flame or temperature in excess of 260° C. (500° F).
Failure to follow these instructions may cause serious injury or death.
NOTE: Due to the usage of magnesium, do not attempt to repair the liftgate inner panel. For further
information refer to Liftgate Inner Panel DO NOT REPAIR
(Refer to 31 - Collision/Standard
Procedure/Non-Structural Sheet Metal Repair/Liftgate Inner Panel DO NOT REPAIR).
Adhesives:
• Safety Data Sheets (SDS) must be available and understood before adhesives are handled.
• All personnel should be instructed on the proper procedures to prevent skin contact with solvents, curing
agents, and uncured base adhesives, which could cause allergic reactions or sensitization.
Types of Structural Adhesives
Overview: There are three basic chemistries used in the collision repair industry. The types of adhesives used
include Acrylic, Epoxy and Urethane. To achieve optimal results, it is best to use the chemistry that bonds best to
the substrate being repaired, is easiest to use and offers the most permanent, non-detectable repair at the most
economical repair cost. All three chemistries have their strengths and weaknesses.
NOTE: Structural adhesives that meet FCA US LLC’s approved replacement materials specifications
include - LORD Fusor 2098, LORD Fusor 112B and 3M 08116
Adhesive Types:
• Acrylic Adhesives - Bond all types of bare metals and are excellent for cross bonding aluminum to steel.
They have good Noise Vibration Harshness (NVH) properties and offer anti-corrosion properties, so primers
must be removed in the bond area. Most acrylics have a fast room temperature cure and respond well to force
curing. They are stable with regards to temperature and moisture during cure. However, both of these can
effect shelf life. Acrylics are the most forgiving of the three chemistries with regards to mix ratio accuracy.
• Epoxy Adhesives - Bond well to ridged and semi-ridged plastics, steel and aluminum and are generally easy
to sand and feather edge. Some may be too ridged for flexible substrates and they often require primers on
bare metal applications. Epoxies can be heat cured to increase strength and accelerate the curing process.
They have a long and stable shelf life. Always purge the air out of the cartridges and use mix nozzles.
RU 31 - Collision Information 31 - 17
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