Ford Galaxy / Ford S-MAX. Manual — part 1084

Wash off and clean the polished location using the professional polishing cloth and then
clean the polished surface.
It is absolutely vital to carry out a visual check after finishing the polishing procedure. If
any swirl marks are not completely removed by the first polishing procedure, then
process must be repeated.

Aids

Cleaning putty

Cleaning putty allows deposits on the paint surface to be removed easily and gently. The
following paint faults can be removed using cleaning putty:

Metal deposits and iron dust.

Paint or color mist.
Tree resin and tar.
Insect residues.

The surface to be worked must be thoroughly cleaned before the cleaning putty can be
applied. Then the surface is sprayed with soapy water. Now the cleaning putty can be slid
over the surface until all unevenness is removed.

Paint - General Information - Painting
Plastic Parts

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

Print

Description and Operation

General

Although these days plastics can be produced in all colors and with a matt or gloss surface,
painting is often necessary.

NOTE: Manufacturer's limitations concerning the feasibility of painting certain components
must always be observed.

Reasons in favor of applying paint to plastic are:

Individual coloring, matching the body paint.
More gloss and color brilliance through painting.
Removal of production imperfections.
Protection from atmospheric exposure.

Nowadays painting plastic presents no problems because the materials are known and
matched to the paint. In order that the painter can use the correct painting materials, the
type of plastic must first be correctly determined.

To allow this, plastics are marked on the rear in accordance with the recommendations of
the Association of Vehicle Manufacturers.

Once the type of plastic is determined it is an easy matter to assign special paint
recommendations, matched to that particular plastic. Unmarked plastics require knowledge
of materials so that a correct choice of paint materials can be made and the component can
be reliably painted.

Plastic groups

Thermoplastics

When warmed these undergo a reversible transformation into a plastic deformable state
and once cooled they maintain their shape. They consist of string-like (linear) or only
slightly branched molecular chains.

Thermosets

Thermosets are hard and have the form of a close-meshed network in all directions. They
do not undergo plastic deformation, are especially resistant to chemicals, are difficult to
swell and are insoluble. At normal temperatures they are hard to brittle. At first the
material does not undergo any change when heated, but when it reaches a critical point,
the thermoset is totally destroyed.

Elastomers

Elastomers are characterized by high elasticity over a wide temperature range. They have
properties like rubber or a sponge and after compression or distension they return to their
original state.

Types of plastic

The plastics used in the automotive area:

ABS - Acrylonitrile butadiene styrene (polymer)
PA - Polyamide
PC - Polycarbonate
PE - Polyethylene
PP - Polypropylene
PP/EPDM - Polypropylene/ethylene propylene diene copolymer
PC/PBT - Polycarbonate/Polybutylene terephthalate

PBT/PC - Polybutylene terephthalate/Polycarbonate
PUR - Polyurethane
GRP - Glass reinforced plastic

NOTE: PE and PP are plastics which cannot be painted, or can only be painted using
special techniques.

As well as the pure plastics, so-called 'blends' are also used. This means combinations of
different plastics. If we were dealing with metals they would be called alloys.

Plastic identification

Normally the identifier is marked on the plastic components used in vehicle construction.

One method to determine the plastic group is the sanding test. In this a place is chosen
which will not be visible later, and the finger belt sander is used to sand the plastic.

The plastic group can be determined using the pattern left by the sanding and the dust:

Thermosets produce a white dust.
Thermoplastics smear and do not produce dust.

The plastic group can be determined by a sound test:

Degree of hardness - the higher-pitched the sound, the harder the plastic.
Elasticity - the more muffled the sound, the higher the elasticity of the plastic.

Cleaning plastic

Plastic components are manufactured using complicated moulds and presses or other highly
engineered tools, mostly using an injection moulding process or reactive injection moulding
process.

In order to be able to remove the component from a particular tool, a separating agent is
used, which in some cases adheres very strongly to the plastic.

This separating agent on the plastic components must be completely removed before any
surface coating is applied.

Warm storage (tempering) before actual cleaning brings the following advantages:

The separating agent sweats out of the plastic.
Tensions in the plastic are released.
Air inclusions can be recognized and removed.

Intensively clean the item several times using a pad and fresh cleaning agent.

NOTE: A single wipe, even with cleaning agent, is not usually sufficient in most cases.
Clean textured components with the aid of a soft brush.

After cleaning, it is absolutely vital that cleaning agent absorbed by the plastic should be
expelled by tempering again. If the ventilation is good and the room temperature is about
20°C the solvent can be evaporated away by overnight storage.

Painting new components

It is absolutely vital that the substrate of an unpainted new component is free of separating
agent. Paint can only be applied directly to very few plastics. The plastic must first be
identified exactly and then worked with a repair system which is matched to the type of
plastic. In most cases a plastic etch primer must be applied as adhesion base to all plastics
which can be painted.

NOTE: Plastics have a tendency to become electrostatically charged. This can easily cause
contamination during painting. Special antistatic cleaning cloths prevent electrostatic
charging.

Work process for thermoplastics:

Thoroughly clean the surface.
Temper the plastic.
Afterwards clean with antistatic cleaner or antistatic cloths.
Apply the bonding agent.
Apply elastic filler. After it has dried, sand and clean.
Apply one coat Uni-paint with elasticizer additive. For two layer painting the elasticizer
additive is in the clear lacquer.

NOTE: Follow the paint manufacturer's guidelines during all work.

Work process for thermosets:

As a rule, thermosets can be handled in the same way as normal body components.

Work process for PUR soft foam:

The work process is the same as for thermoplastic.
Instead of using bonding agent, a filler wash is applied to close the pores of the PUR soft
foam.

The primer which has been applied to a primed new component can vary greatly. If no
manufacturer's data is available, the composition and suitability for further working must be
tested.

Painted components with an already ascertained and intact paint coat present no problems
for possible repainting. After sanding and careful cleaning with plastic cleaner or thinners,
painting can be done directly.

Unknown primer

When dealing with unknown substrates it is important to carry out an adhesion test on the
existing paint before any repainting is attempted. First of all a mechanical test must be
carried out, for instance using a lattice cut and tear-off band. If the adhesion of the old
paint is not acceptable, it must be mechanically removed and new paint finish applied.

If the adhesion is acceptable, then an etch test is performed using 2-component thinners. If
no etching can be detected in this test, application of the the paint finish can be started
directly. Otherwise the old paint must be removed and a new paint finish created.

With the help of universal or special plastic primers and with only a few materials
complementary to those previously present anyway, the painter can now apply a long-
lasting paint finish to all popular vehicle attachments made of plastic.

Paint faults on plastic substrates

NOTE: Paint faults are fully described in the chapter Paint Defects and Damage.

The most common paint faults which can occur when painting plastic components and the
methods of repair are briefly described.

Discoloration

Cause/damage pattern:

Plastic material is not suitable for painting.
Incorrect bonding agent.
Paint used not solvent resistant.

Repair of damage:

Repaint using suitable materials.
Install a new unpainted component.