(5) If desired, a thin film coat of adhesive ca n be
applied to the back of th e pa tch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a pa per or cardboard pat tern the size
and sha pe of the cutout hole in the pa nel.
(2) Trim 3 mm (0.125 in.) from edges of patt ern so
pa tch will h ave a gap bet ween conn ectin g surfaces.
(3) Usin g the pattern as a guide, cut the pat ch to
size.
(4) Cut scra p pieces of patch mat eria l into 50 mm
(2 in.) squ ares to use as patch support s to su st ain
the pa tch in th e cutou t.
(5) Drill 4 mm (0.160 in.) h oles 13 mm (0.5 in .) in
from edge of cutou t hole (F ig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 m m (0.5 in .)
away fr om edge of patch acr oss fr om holes drilled
around cutou t.
(7) Drill 3 mm (0.125 in .) holes in t he su pport
squar es 13 mm (0.5 in.) from the edge i n th e center
of one side.
(8) Scu ff th e backside of the body panel ar ound t he
cutout hole with a scuff pad or san dpa per.
(9) Mix enou gh adhesive to cover one side of all
su pport squ ares.
(10) Apply a dh esive to cover on e side of a ll support
squa res.
(11) Usin g nu mber 8 sheet metal scr ews, secur e
su pport squar es t o back side of body pa nel with
adhesive sandwiched between the pa nel and squ ares
(Fig. 9).
(12) Posit ion pa tch in cutout against su pport
squar es and a djust pat ch u ntil t he gap is equa l a long
all sides (Fig. 10).
(13) Drill 3 mm (0.125 in.) holes in th e support
squar es through th e pre-drilled holes in the pa tch.
(14) Apply a coat of adhesive to t he exposed ends
of the support squa res (Fig. 11).
(15) Install scr ews t o h old the patch to support
squar es (F ig. 12). Tighten screws unt il patch su rface
is flush with pan el surface.
(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 gr it disc grin der,
grind a 50 mm (2 in.) t o 75 mm (3 in.) wide and 2
mm (0.080 in.) deep pa th across t he ga ps ar ound th e
pa tch (Fig. 13). With compressed air, blow dust from
around patch.
(18) Apply adh esive backed nylon mesh (dry wall
tape) over ga ps around patch (Fig. 14).
(19) Mix enough adhesive t o cover the entire pat ch
area.
(20) Apply adhesive over t he mesh around pa tch,
and smooth epoxy wit h a wide sprea der to redu ce fin-
ish gr inding. Use two t o t hree la yers of mesh and
adhesive to creat e a stron ger repa ir (Fig. 15).
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 9 SECURE SUPPORT SQUARES TO BODY
PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
23 - 8 BOD Y VA
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