Dodge Nitro. Manual — part 378

Fig. 4: Beveling 20 Degree Angle
Courtesy of CHRYSLER LLC

When repairing plastic, the damaged area is first "V'd" out, or beveled. Large bonding areas are desirable when
repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a
20° angle will increase the bonding surface for a repair. It is recommended that sharp edges be avoided because
the joint may show through after the panel is refinished.

2007 Dodge Nitro R/T

2007 ACCESSORIES AND EQUIPMENT Body - Nitro

Fig. 5: Applying Fiberglass Tape
Courtesy of CHRYSLER LLC

Panel repair for both flexible and rigid panels are basically the same. The primary difference between
flexible panel repair and rigid panel repair is in the adhesive materials used.

The technician should first decide what needs to be done when working on any type of body panel. One
should determine if it is possible to return the damage part to its original strength and appearance without
exceeding the value of the replacement part.

When plastic repairs are required, it is recommended that the part be left on the vehicle when ever
possible. That will save time, and the panel will remain stationary during the repair. Misalignment can
cause stress in the repair areas and can result in future failure.

VISUAL INSPECTION

2007 Dodge Nitro R/T

2007 ACCESSORIES AND EQUIPMENT Body - Nitro

Fig. 6: Identifying Damaged Component
Courtesy of CHRYSLER LLC

Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors,
and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may
require partial removal of interior trim or inner panels.

Identify the type of repair: Puncture or Crack - Damage that has penetrated completely through the panel.
Damage is confined to one general area; a panel section is not required. However, a backer panel, open
fiberglass tape, or matted material must be bonded from behind.

PANEL SURFACE PREPARATION

If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to
achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or
removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away
from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces
around the damaged area should be stripped of paint and freed from wax and oil. Scuff surfaces around repair
area with 360 grit wet/dry sandpaper, or equivalent, to assure adhesion of repair materials.

PATCHING PANELS

1 - PUNCTURE

2007 Dodge Nitro R/T

2007 ACCESSORIES AND EQUIPMENT Body - Nitro

Fig. 7: Identifying Damaged Panel Cutout and Patch
Courtesy of CHRYSLER LLC

A panel that has extensive puncture type damage can be repaired by cutting out the damaged material. Use a
suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out
can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to
install a patch. Bevel edges of cutout at 20° to expose a larger bonding area on the outer side. This will allow for
an increased reinforcement areas.

PANEL PATCH FABRICATIONS

1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE

2007 Dodge Nitro R/T

2007 ACCESSORIES AND EQUIPMENT Body - Nitro