Ford Fiesta (2011 year). Manual — part 168

adhesion defects can only be noticed after an
external influence such as stone impact.

Cause/damage pattern:

• Substrate not adequately prepared (rust, grease,

moisture, sanding, cleaning).

• Unsuitable material used.

• Drying times, flash-off times too short.

• Base paint not sprayed wet-in-wet, instead the

intermediate drying times were too long.

• Failure to intermediate sand.

• Condensation formed because of temperature

fluctuations.

• Unprofessional preparation (especially on

plastics).

• Overheated CDP/intermediate filler.

Repair of damage:

• Sand out the damage and recreate the paint

finish. Create the paint finish strictly in
accordance with the general technical
information.

Adhesion defects in clear lacquer.

Clear lacquer detched from base paint.

Cause/damage pattern:

• Base paint layer too thick.

• Intermediate and final flash-off times of base

paint too long.

• Incorrect mixture ratio clear lacquer/hardner.

Repair of damage:

• Refinish sanding and recreate the paint finish.

Sanding scores

Single or wide area clusters of scoring or sanding
marks, often with raised edges. Noticeable on
metallic paints as light-dark stripes.

Cause/damage pattern:

• Stopper sanded too coarsely.

• Filler sanded too coarsely.

• Filler not thoroughly dried bfore sanding.

• Old paint sanded too coarsely.

• Soft elastic substrates, e.g. TPA base, treated

with thinners which was too aggressive and
therefore etched.

• Top coat applied too thinly.

Repair of damage:

• If the damage pattern is minimal, after the top

coat has dried fine sand the paint surface and
refurbish by polishing.

• If the damage is great or on metallic paints, sand

the paint surface or substrates and if necessary
remove them, then cover the bare metal and
re-paint.

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Formation of stripes

Differing, stripe shaped color/effect formations in
dark/light areas of a metallic paint finish.

Cause/damage pattern:

• Spray gun (nozzle) not perfect.

• Incorrect spray pressure.

• Thinners not suitable.

• Incorrect spray viscosity.

• Flash-off time too short.

• Unsuitable working temperature.

Repair of damage:

• Apply base paint evenly.

• Repair spray gun.

• After clear lacquer has thoroughly dried, sand

surface and paint again.

Peeling/blistering on plastic parts

Paint adhesion insufficient between top coat and
filler and/or primer layer. It often happens that the
whole of the paint finish detaches from the plastic.

Cause/damage pattern:

• Plastic item not cleaned sufficiently, not or

inadequately tempered.

• Unsuitable cleaning agent used.

• Unsuitable materials used.

• Moisture.

• Paint finish underbaked or overbaked.

• Poor or lack of intermediate sanding.

Repair of damage:

• Sand away faulty paint coats and re-apply paint

finish.

• In extreme cases use a new part.

Blistering on polyester material

Color shade differences or marks in paintwork
subsequently applied to previously unpainted
plastic material.

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 unpainted new part (after consulting

customer).

Peroxide marks in metallic paints

After longer period of drying, abnormal marks
where the color shade varies.

Cause/damage pattern:

• Too much hardener added to polyester stopper

(over 3% can cause this damage pattern).

• Polyester stopper not well enough mixed.

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Repair of damage:

• Sand, fill with polyester or epoxide filler and

re-paint.

Crack formation

Cracks of different lengths and depths running in
all directions.

Cause/damage pattern:

• Layers too thick.

• Painted several times.

• Temperature fluctuations.

• Mechanical effects e.g. distortions.

• Substrate not thoroughly hardened.

• Old paint not completely dried out.

• No or insufficient hardener added.

• 2-component materials used on nitro or TPA.

Repair of damage:

• Sand away layers until sound substrate is

reached and create new paint finish (prime, fill,
apply topcoat).

Shrinking back/zone edge marks

Lifting or dropping in of edge zones (edges which
accentuate themselves in the top coat), flow
problems and loss of shine in top coat.

Cause/damage pattern:

• Old paintwork not rubbed down to a seamless

transition.

• Stopper and filler on a viscoplastic base primer.

• Filler sanded and overpainted when not

thoroughly hard.

• Previous materials overworked too early,

substrate not sufficiently hardened.

• Primer applied in layers which were too thick,

and not dried for long enough.

• Sanding paper too coarse.

• Top coat thinned too much.

Repair of damage:

• After hardening off the top coat, fine sand the

surface and polish up, apply filler if necessary
and paint once more.

Blistering

Small, spot-like, air-filled or water-filled blister
shaped high-spots in the paint construction. Their
dimensions can range from pin-head to pin-point
size in a closed paint film. Arrangement and
accumulation very variable. In the advanced
stages, circular flaking of the paint from the
substrate. These are neither boils nor corrosion.

Cause/damage pattern:

• Moisture absorption by substrate.

• Insufficient drying of the substrate after wet

sanding (especially on polyester material).

• Humidity too high before painting; condensation

formation because of temperature fluctuations.

• Pores/sink holes in substrate not sanded out.

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• Polyester material not covered.

• Sweat from hands.

• Salts and minerals in sanding water.

• Spray air contaminated.

Repair of damage:

• Sand away damage, matt sand remainder of

surface, clean with silicone remover, fill and
re-paint.

Etching

The base paint is etched by the clear lacquer. This
causes the aluminum pigments to change their
alignments. The color of the etched base paint
seems more grey than that of normal base paint.
Result is that the surface structure of the clear
lacquer becomes increasingly more matt.

Cause/damage pattern:

• Base painted too wet.

• No intermediate flash-off time.

• Layers too thick.

Repair of damage:

• Sand and re-paint.

Paint wrinkles/puckering

Lifting/puckering of the paint surface.

Cause/damage pattern:

• First paint not hardened through or can be

etched.

• Areas of clear lacquer which were sanded

through to base paint have not been not isolated
with filler, or with unsuitable filler.

• Unsuitable substrate (e.g. spray can painting

with TPA or nitro).

• Use of unsuitable primer, paint and thinner

materials.

• Paint systems not matched to each other.

• In wet-in-wet process, specified flash-off times

not adhered to.

• Synthetic resin top coat (alkyd resin) worked

over too soon.

Repair of damage:

• After thorough drying, completely remove the

top coat together with the attacked substrate at
the affected areas and re-create a new paint
finish.

• Before applying top coat, rub down the complete

surface.

Cloud formation

Differing, blotchy color/effect formations in
dark/light areas of a metallic paint finish.

Cause/damage pattern:

• Spray gun, spray nozzle, spray pressure not

perfect.

• Varying spray viscosity, spraying method,

flash-off times, spray booth temperature.

• Thinners not suitable.

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