Mitsubishi Evolution X. Manual — part 11

CORROSION PROTECTION

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BASE OF BODY REPAIR

9-41

2. Use a brush to apply spot sealer to the contact surfaces of

the panels (both the new panel and the panel remaining on
the body) to be spot welded.

3. Do not spot welding.

NOTE: The spot welding can be done as the spot sealer is
dry to the touch.
Dry to the touch: 30 minutes or less at 20

°

C (68

°

F)

BODY SEALING

Even if a car body is restored to the exact specified dimen-
sions, the body repair work cannot be considered to be com-
plete if an ample amount of sealant is not applied to each of the
panel joints and seams. Insufficient sealant will result in water
leakage, corrosion, etc.
NOTE: Use a piece of clean cloth dampened in lead-free gaso-
line or a similar material to clean parts and areas where sealant
is applied.

• When applying sealant to areas at which the external

appearance is important (areas which can be seen or where
the condition of the paint coat is important), be sure to apply
the sealant so that it is perfectly level with the surrounding
panels.

• Apply the sealant at the fuel port so that it is perfectly level

with the surrounding panel so that drops of fuel will not col-
lect.

AB200119

AB200120

AB301490AD

Clean away
any excess

AB301490

AB200122

CORROSION PROTECTION

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BASE OF BODY REPAIR

9-42

• After applying sealant to the door-stop, etc., clean away any

excess so as to be sure that there is no interference with
installed parts, etc.

UNDERCOATING

• Be sure to mask any parts installation holes, and

the area around the place where undercoating is
to be applied, before applying it.

• Be sure not to apply the undercoating to tires or

to the drive shaft and other drive components.

If the undercoating application inside the wheel
housing, on the under body, etc., is insufficient, it can
result in corrosion. Be sure, therefore, to apply a
good coating of undercoating to such parts after
repairs are completed.

AB200123

AB301464

: Undercoating application locations

AD

AB301464

REPAIR OF SYNTHETIC-RESIN PARTS

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BASE OF BODY REPAIR

9-43

REPAIR OF SYNTHETIC-RESIN PARTS

SYNTHETIC-RESIN PARTS REPAIR PROCEDURES

M4090000300090

Bumper is taken as a repair work example for expla-
nation.

FLOWCHART

AB401319

Hole (diameter 50 mm
(1.97 in) or smaller)

Crack, tear (length
200 mm (7.8 in) or smaller)

Scratch (length 200 mm x
width 120 mm (7.8 x 4.7 in)
or smaller)

1. Cleaning

2. Reshaping of damaged area

3. Fixing of glass cloth (backing)

5. Base surface preparation (surface grinding)

6. Rough grinding

7. Filling (putty application)

8. Surface grinding

9. Surface preparation for primer-surfacer

12. Primer-surfacer coating

13. Primer-surfacer grinding

10. Cleaning and degreasing

11. Masking

AB

4. Adhesive application

14. Coating

AB401319

REPAIR OF SYNTHETIC-RESIN PARTS

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BASE OF BODY REPAIR

9-44

REPAIR JUDGMENT

.

REPAIRABLE AREA

• In case of a hole, the damaged area is reshaped to be a cir-

cle or ellipse for easier filling of the repair agent. The diame-
ter or major diameter should be 50 mm (1.97 inches) or
smaller.

• In case of a crack or tear, if the both ends of the crack or

tear are not separated from the body, the length of the area
should be 200 mm (7.8 inches) or smaller. If one of the ends
reaches the bumper edge, the length of the damaged area
should be 200 mm (7.8 inches) or smaller, and also the
width should be a half or less of the bumper width.

• In case of a scratch, the area should be 200 x 120 mm (7.8

x 4.7 inches) or smaller.

.

UNREPAIRABLE COMPONENTS

Black-base area is raw urethane base and repairable, however,
its color does not match in color of the repair agent (ash gray).
In this case, the replacement of the bumper is preferable.

.

BUMPER REMOVAL AND CLEANING

• The damage of holes, cracks, and tears requires a repair

work from the rear surface. Remove the bumper to clean
the whole surface, degrease the front and rear surfaces of
the repair area using SU Silicone Off, and then repair, hold-
ing the bumper to avoid twisting.

• In case of a scratch, a softener is applied to the bumper as

repair paint. The repair area cannot be polished after paint-
ing, and surface/gloss matching is difficult. Therefore, do
not apply gradated topcoat painting, and paint the whole
surface as a rule.

REPAIR PROCEDURE

.

1. CLEANING

Using SU Silicone Off, degrease the repair area, and then
remove the wax and oil completely.

.

AB401311AB