Ford Galaxy / Ford S-MAX. Manual — part 1085

Softening

Cause/damage pattern:

Substrate not carefully cleaned.
Air humidity too high or working temperature too low.
Drying time incorrect (too short).
Materials for substrate not correctly matched to each other or not mixed correctly.

Repair of damage:

Dry out, sand, re-isolate and paint.
Sand away faulty paint coats and re-apply paint finish.

Paint damage caused by detachment, poor adhesion

Cause/damage pattern:

Insufficient paint adhesion between top coat and filler. The whole of the paint finish
detaches from the plastic.
Plastic not cleaned sufficiently, not or inadequately tempered.
Unsuitable cleaning agent or materials used.
Poor or lack of intermediate sanding.
Paint finish underbaked or overbaked.

Repair of damage:

Sand away faulty paint coats and re-apply paint finish.

Paint damage caused by blisters, craters, sink holes

Cause/damage pattern:

Painting on PUR plastic which was not painted in production.
Surface of the plastic material too porous.
Flash-off time not adhered to.
Drying temperature too high.
Moisture in plastic material.
Layers too thick.

Repair of damage:

Clean the damaged area, sand, re-isolate and paint.
Remove the paint layers and re-paint.

Crack formation

Cause/damage pattern:

Overexpansion of painted PUR plastic components.
Use of unsuitable paint materials.
Paint materials not suited to each other or incorrect mixture ratio.

Repair of damage:

It is not possible to repair overexpanded PUR plastic components.
On other plastics, sand away damaged layers, isolate and repaint.

Paint - General Information - Spot Repairs

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Description and Operation

General

In general, partial surface painting at a point is called a spot repair. Using this technique,
minor paint damage can be resolved economically and to time.

Advantage of this method

Because this application remains confined to the area of the damage, it is often
unnecessary to remove components or color match against neighboring components. The
material used is very much reduced because only a part of the repair area is coated.

Practical application areas

Only occasionally can satisfactory results be achieved in the centre of larger surfaces
and/or on difficult colors. In addition, unprofessional application may cause tear-off edges
to appear in clear lacquer. Only certain application areas are recommended.

NOTE: The final decision on whether to spot repair or paint the component must be made
by an expert.

Application areas:

2-layer paint.
Depending on the damage zone, paint damage up to a diameter of 3.5 cm or a length of
10 cm.
Scratches.
Clear lacquer application up to an area of DIN A4 max.
Smaller areas which are optically broken up by other components such as trim strip, tail
lights, swage lines and edges.
Boundary zones and edge areas of larger components.

The best application areas have proven to be optical break lines such as corners, narrow
surfaces, fenders and wheel arches.

Because of their locations, the violet colored areas are the most suitable for spot repair
painting. The turquoise areas are only marginally suitable and the rest of the areas are not

suitable for spot repairs.

Repair process

Perfect preparation of the subsurface is the precondition for a brilliant paintwork result.
Faults in the preliminary stages delay completion and cause unnecessary extra work. The
working steps described here demonstrate how important it is to follow these instructions
step by step.

Illustration of damage

A typical case for spot repair is a small stone chip on the fender.

Cleaning

First of all the component is thoroughly cleaned using silicone remover and refurbished
using abrading and polishing paste. This re-creates the original degree of shine and ensures
exact color matching on the touch-up surface.

Sand out

Sand out the damaged location using P180 - P320. Only small sanding blocks and small
sanding machines must be used, so that the area of the repair remains as small as
possible.

Sanding is completed by rubbing down the surrounding surface with a fine sanding pad or
P1000 paper. Remove sanding residues and clean the repair area with silicone remover.
The peripheral zone must then be masked for application of the filler.

NOTE: The size of the repair area must be kept as small as possible (maximum size DIN

A4).

Filling

The filler layer is applied in stages. First of all, filler is only applied to the location which has
been sanded away. After a wait time for flashing off, the second coat is applied so that it
spreads over onto the existing paintwork.

The filler must be dried according to the instructions of the material supplier.

Rubbing down

The repair location is now rubbed down with P400 - P500 and the bordering surface with
P2000 - P4000. Remove sanding residues and clean the repair area with silicone remover.

Paint

Before painting, clean the area for the final time using a dust-bonding cloth. Then apply the
basic paint in thin layers using a spray gun until enough coverage is achieved.

After drying, apply clear lacquer in 1 or 2 coats (depending on product). In doing so, spray
so that only the newly applied basic paint is completely covered. Finally a touch-up thinners
is sprayed over the edge of the clear lacquer to dissolve the clear lacquer spray mist.

Dry