Discovery (1995+): Body Repair Manual — part 38
PANEL REPAIRS
3
PANELS
SUBSTRATE
ALUMINIUM PANELS
PANEL REPAIR
REPLACEMENT PANEL
PREPARATION
Wet for using P60 Grade paper or dry sand using
P240 grit discs.
Wet flat using P60 Grade paper or dry sand using
P240 grit discs.
Care must be taken to avoid cutting through to bare
aluminium.
BODY FILLING
If filling is required, thoroughly abrade bare aluminium
area to be filled and apply Standox Polyester
If filling is required, fill small indentations with Standox
Polyster stopper 430-5029.
ETCHING
This process is not required if the original electrocoat
primer is in sound condition.
IF NOT
Etch the bare aluminium and filler with auto-speed self
etch primer 414-1171, mixed 1:1 with activator
801-7995. Apply one coat and allow to dry for
approximately 20 minutes. Recoat within 1 hour.
PRIMING
To obtain maximum adhesion and excellent build, apply
Standox 2K 4:1 full primer 405-0381. Coats of 30-40 microns
can be wet flatted with P60 grade paper after 45 minutes at
20˚C.
COLOUR COATING
Apply either Standox 2K Standocryl or Standox Metallic
Basislack to the colour required. Hardeners and thinners will
vary depending upon system employed, conditions available,
temperature and size of vehicle etc. Refer to paint
manufacturers Technical Information Sheet for correct
selection.
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PANEL REPAIRS
4
PANELS
SERVICE CONDITION OF PANELS
Bodyshell (3- and 5-Door)
Bodyshells, which are also supplied with sunroof
aperture are serviced less front wings, bonnet, side
door assemblies and rear door.
Front Panels
Front panels are serviced as a complete assembly (1)
including a bolt-on bonnet lock platform. The following
parts are also available separately: headlamp panels
2, 3) and cross brace (4).
Valance and Wheelarch
Valance and wheelarch panels are serviced as an
assembly (1) and fitted to the bulkhead. The following
parts are also available separately: closing panel (2)
and battery mounting panel (3).
PANEL REPAIRS
5
PANELS
Wing Extension Panel
Wing extension panels are serviced as separate parts,
and are fitted to the valance and wheelarch.
Front Wing
Front wings are serviced as separate bolt-on
aluminium panels.
Bonnet
Bonnets are serviced less hinges which are available
separately.
’A’ Post
The ’A’ post assembly is fitted to the bulkhead, dash
side panel and inner sill.
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PANEL REPAIRS
6
PANELS
’BC’ Post
The ’BC’ post assembly is fitted to the inner sill and
cant rail.
Outer Sill
Outer sills are serviced as a complete panel.
Body Side Closing Panel (3-Door only)
Body side closing panels are serviced as a complete
panel.
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