Ford Falcon. Manual — part 488

501-25B-2

Body Repairs — Corrosion Protection

501-25B-2

DESCRIPTION AND OPERATION

Readily flammable overalls or gloves must not be

Electro — Coat

worn during welding operations. In addition, fuel

lines, tank and any other flammable materials

All panels supplied are E-coated in the plant. This is

including wiring looms must be removed if welding

an anti-corrosion paint, not a surface primer. All

is to be carried out in the vicinity.

panels must be lightly scuffed and painted with a two

pack primer or primer filler (to improve appearance

When carrying out welding and similar operations,

and to prevent top coat peeling) and then receive

overalls etc., made of Nylon, Perion, Dralon, etc.,

normal treatment up to finish coat.

must not be worn.

Fitting new panels require the removal of E-coat

where welding is required and the use of a

weld-through zinc rich primer.

Corrosion Prevention

Vehicles requiring body repair must have the

anti-corrosion protection reinstated during the repair.
The level of protection required and the

recommended materials are contained in the following

pages.
Care should be taken when substituting other type

materials, that they will not cause a long term

problem, e.g,. Acid curing silicons will promote

corrosion when used in contact with painted or bare

metal panels.

Corrosion Protection

Safety Precautions

Anti-corrosion treatments, waxing agents and plastics

used in vehicles produce vapours when heated which

may cause serious injury if inhaled.
In addition to the normal requirements for a safe work

place, ensure the following precautions are observed:

Keep a fire extinguisher within reach. This safety

precaution must be taken although the

anti-corrosion treatments generally do not

constitute a direct fire risk.
Remove anti-corrosion treatments as far as

possible from the vicinity of the area to be welded.

Polyurethane hard foam can be removed with

cutting tools, wax and underseal are preferably

removed using sanding discs or , wire brushes.

Wax and underseal can also be removed usinf a

hot-air-blower of the kind employed by decorators

when laying plastic floors.
If anti-corrosion treatments cannot be removed

due to lack of space or inaccessibility, fumes and

gases produced during welding operations must

be extracted directly. This is best accomplished

with special extractors with suction heads on

flexible hoses that can be conveniently positioned

in the working area.
Welding operations should always be carried out

in seperate, well ventilated areas. Breathing

masks must always be used.
A hole should be drilled in cavities filled with hard

foam on the side away from the operator so that

vapours can escape.

G33920 en

501-25B-3

Body Repairs — Corrosion Protection

501-25B-3

GENERAL PROCEDURES

Soft Seal Locations

Item

Description

1

Seal

2

Sealer Bead

G33923 en

501-25B-4

Body Repairs — Corrosion Protection

501-25B-4

GENERAL PROCEDURES (Continued)

G33923 en

501-25B-5

Body Repairs — Corrosion Protection

501-25B-5

GENERAL PROCEDURES (Continued)

Anti — Flutter Adhesive Location

Item

Description

1

Anti Flutter Adhesive – 6.0 to 8.0 mm Dia.

Bead

2

Metal to Metal Adhesive 1.5 to 2.5 mm

Bead

3

Panel Hood

G33924 en