The Car Bodywork Repair Manual: A Do-it-yourself Guide to Car Bodywork Repair, Renovations and Painting (A Foulis motoring book) 0854293736, 9780854293735

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Repair

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Renovation

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Painting

I'd /ike to dedicate this book to my wife, Shan. Most of the jobs covered here were carried out in our workshop, next to our house, and since the book has taken several years to prepare, she has put up with a lot! She also checked and typed the manuscript and took many of the photographs, and so there's a lot of her in here,

Books on the f ollow ing specific vehicles are available in the 'Guide to Purchase & DIY Restoration' seri es by lindsay Porter fro m t he Haynes Publishi ng Group,

MGB (F303) MG Midget & Austin-Healey Sprite (F336) Mini (F379) Morris Minor & 1000 (F442) Available soon:

V. W. Beetle (F4 74) IS BN 0 85429 373 6 ISBN 0 85429 486 4 (trade edn.) ISBN a 85429 530 5 (US paperback adn.) A FO UUS Motoring Book First published 1985 Reprinted November 1985 and March 1986 CI lindsay Poner and Haynes Publishing Group 1985 All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical. including photocopying, recording or by any information slorage or retrieval system, without permisSion of the publisher. PUblished by: Haynes Publishing Group Sparkford, Yeovil, Somerset BA22 7JJ. England Haynes Publications Inc. 861 Lawrence Drive, Newbury Park, California 91320 USA

Editor: Mansur Darlington Printed in England by: J.H. Haynes & Co. Ltd

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Acknowledgements If any person could claim to know

every scrap of information carried in this book, I'd like to shake him warmly by the hand I There' s so much here thaI

I certainly couldn', claim to be an expert in it all and a great deal of help was freely given by those mentioned below and by many others over the years it took to pul all the pictures and

information together. Many companies have lent their

expertise but none more th9n SIP (Industrial Products) ltd whose welding and spraying equipment has given sterling service. Marketing

Director Peler Osborne. a man with both engineering and journalism in his blood, has been unfailingly courteous. friendly and an unerly dependable source of technical information, while Paul Toon has busily set up photographic sessions and supplied pictures at the drop 01 a hat. International Paints' training school and technical slaff sel up some highly informative photo sessions, aided by Ihe planning skills of David Edwards of Leedell, International's PR consultant. At De Vilbiss, the company whose founder invented the paint spraying idea, George Mooney and Ian

Bonker were as helpful and informative as can be and I am grateful for the opportunity to use some of the ellcellent graphic materials produced both by International Paints and by De Vilbiss. At Murell Ltd, Les Ness kindly arranged the opportunity to photograph a 'how· to ' welding session, and the Portapack, produced in conjunction with BOC, has proved to be a super piece of equipment. Much information on gas welding from BOC and from Murell is contained within this book and I am grateful to them both. In that department, Sifbronze have also kindly given their advice. Tools from Apollo, The Welding Centre, Sykes· Pickavant and Black and Decker have all been used in the situations depicted here and all have been found to be ellcellent, while materials and equipment from Supra, Unipart and Holts have all been found to give ellcellent results. CARS of Stourport, Tudor W ebasto, Smith & Deakin, Vehi cl e Wi ndow Centre, Celene Churchill, Clearview Windscreens and Berger Paints all set up photographic situations or supplied pictures and

technical information and Austin -Rover kindly allowed me access to many of their in·house line drawings, and Paul Sanderson/Practical Classics Magazine were similarly helpful. Also most helpful in arranging work for photographic sequences was John Hill's MGB Centre at Redditch. My gratitude to my wife Shan for all her help and incredible forbearance is reflected, I hope, in the Dedication at the front of this book, Diane Hayton also typed a goodly number of pages, so thanks are due to her too. Scott Mauck and his team at Haynes Publishing Inc. in California were tremendously helpful in taking pictures at the locations mentioned in the lelll while my fina l 'thanks' goes most gladly to Mansur Darlington w ho has undertaken the eno rmous task of editing this complex book with commendable stOicism and enviable efficiency and in so doing has done an awful lot to ensure that the whole package looks as good as i like to think it does. Addresses of the companies mentioned here and others who have contributed to this book are given at the back of the book,

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Using this book Sometime during the life of every car the bodywork is going to suffer damage of one sort or another, whether it be externally as a result of impact, or internally due to corrosion. Car body problems come in all shapes

and sizes from the tiniest scratch through to crash damaged repairs, so there's a lot of ground to cover. In addition to being divided into chapters in the normal way. to help you to find the information you need, when you

need it, this book has been split loosely into two kinds of sections which are mixed throughout the book. The first

to show you all the safe ways out and leave you to choose, basing your decision upon your own aptitude, the value of the car, the equipment at your disposal and so on. To differentiate between the two types of Section a coding is used, starting in the Contents list and carried through to the main headings right throughout the book. The 'Project' Sections are indicated by a • against their headings; Technique' Sections are indicated by a • . To find information on a particular topic go first to the Contents list on pages 5-7, where the contents are listed Chapter by Chapter. Because, however, many of the skills and disciplines required in bodywork repair are interlinked, additional useful information on a particular topic will also be found outside the main topic Chapter. Thus, after the main Chapter contents cross-references are given under the heading 'More Hints, Tips and Information', Apart from the above, it is worth reading and digesting the following points jf you hope to get the maximum use out of the book.

kind is all about 'Techniques', in which is given enough background for you to know where you're going. get-youstarted picture sequences and then some more advanced information in case you come across awkward problems and for when you want to take your new skills a stage further. Having the skills is great, but putting them to use could be something elsel That's why there are sections of a second sort dealing with 'Projects', Project sections show you specific skills or techniques being put to use on real cars, in real-life circumstances where actual rust or accident damage has taken place, Each Project section is fully illustrated with .1) Each chapter is sub-divided step-by-step pictures of how the into sections. Section headings are in italic type between hori.zontal experts tackle a job, but in way that the home repairer can follow and use. lines and sub-section headings are similar. but without horizontal lines. There has been no attempt to gloss over the problems that come up: you can see for yourself they can occur and what to do about them, and where 2) Photograph captions and those for there is more than one way round a sequences of line drawings are an problem, this book gives it. Quite often integrar part of the text and there is a cheap 'n' cheerlul way or therefore the captions are arranged repairing car bodywork or there is the to read in exactly the same way as the normal text. In other words they high quality approach; the aim here is

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run down each column from left to right of the page. Each caption carries an alphanumerical identity, relating itto a specific section. The letters before the caption number are simply the initial letters of key words in the relevant section heading, whilst the caption number shows the position of the particular photograph or line drawing in the section·s picture sequence. Thus photograph/caption 'DR22' is the 22nd photograph in the section headed 'Door Repairs·, 3) Figures - illustrations which are not

integral with the text- are numbered in a manner similar to the photographs. Thus, Figure FWR 1 will be the first figure relating to the ' Front Wing Repair' section. 4) We know it's a boring subject. especially when you really want to get on with a job - but your Safety, through the use of correct workshop procedures, must ALWAYS be your foremost consideration. It is essential that you read, and UNDERSTAND, Safety Sense on pages 17 -19 before undertaking any of the practical tasks detailed in this book.

Whilst great care is taken to ensure that the information in this book is as accurate as possible, the author, editor or publisher cannot accept any liability for loss, damage or injury caused by errors in, or omission from, the information given.

Contents 4

U sing this book

3

Acknowledgem ents

•

Body language Tools & Equipment

12

"

Safety Sense

Ch. 3 Ru st Treat ment & Proofing

More HinU, Tips and I"formation

Safely -

SII

'Safety Sense"

Weld-on wings (remOlle end fid-

see eh. 5 Bodywork Repairs Weld-on DIY patch panel - see eh. 5 Bodywork Rep.i,. Weld-on DIY Patch Panel- see eh. 4 Painting: Part 2 (Brush-painted bodywork) Chassis and sublrilme welding 58e eh, 5 Bodywork Repairs

•

" • ••

136

143

• • •• •

Introduction to Welding and Brazing Types of Welding:

."

Carbon-a rc OJly-acetylene MIG riG Selecting your Welding Gear Welding Concepts and Principles: Compatibility Distortion Impurities Joint types Welding Techniques: Arc - including overhead welding Carbon-arc brazing OKy-acetylene welding inctuding rod and wire thickness chan, and shuning-down procedure OKy-acetylene cutting Hints on welding stainless steel Hims on brazing aluminium alloys OJly-acetylene brazing Heat shrinking a panel TIG welding MIG welding MIG-welding in Awkward Places MIG-spot welding

20 20 21 21 21 21 21

22 22 23 23 24

2.

29 36 3. 3. 39 39 41 41 46

46

•••

• • ••

Introduction to Panel ｂ･ｾｴｩｮｧ＠ Metalworking Techniques Mallets Application 01 Dolly and Beater Spoons and Their Applications Panel Finishing Annealing

Mor/! Hinls, Tips ilnd In{Olmarion Safety - see 'Safety Sense' Using Body Solder; Using Body Filler; Body Finings; Removing Stubborn FiJlings; Light Crash Repair - front "damage; Light Crash Repair - skle damage; Filling a Replacement Bolt-on Wing (including dent removal): Renewing a Door Skin; Bonnet Front Damage. Repair: Front Wing Damage Repair - All Ch. 5 Bodywork Repairs Simple dent removal techniques - see Ch. 4 Painting : Part 2 (Respraying II Rear Wing) Dent removal - double skinned panel - see Ch. 6 Repairs On A Shoestring. (dent removal)

and treatment

54 54

57

More Hints. Tips and

102

Informarion

Safely - see 'Safety Sense'

".

Cutting Out Rust; letting-in and

49 50

Blast Cleaning linc. Sand Blastingl - see Ch. 5 Bodywork Aepsif3 Cutting Out Rust - short term panel and paintwork repairssee Ch. 6 Repairs On A Shoestring (Cu tting Out Rust. etc): and (Bodywork Repair and Improvement From A Canl Painting inside iI door (whilst being re-Skinnedl- see Ch. 5 Bodywork Repairs (Renewing B Door Skin I Using undershield - see Ch. 6 Repairs On A Shoestring

deal with hI

51 51 51

52 53

"

"

welding II repair patch - see eh.4 Painting: Part 2 (Brush Painted Bodyworit - how to

C h. 2 Penel S •• t ing eh. 1 W elding

How Corrosion Occurs Fighting Back Rustproofing - Wi,. injection

102

167

172

". 140 191

Ch . 4 Painting : Part 1

•• •• • • •• •• • •

,. 106

94

,.4

Gun lore - types of spray gun Choose your Weapon Cleanliness Comes Last I Principal parts of the Spray Gun Pulling on the paint Paint - its constituents Vehicle Manufacturer's Paint Types Refin ish Paint Types Clear-over-Base Finish UndercoatS Pre-Spra y Garage Preparation Preparing 10 Spray - intluding test for paint type Fratting (or ｓ｡ｮ､ｩｧｾ＠

140 64 65 67

6. 6. 69 69 70 70 71 72 73

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The Car Bodywork Repair Manual

•• •• ••• •• ••• •

How to Flat Masking Off

Preparing to Paint - summary Spraying the Primer

Spraying the Colour Coal Start Spraying I

74

74 74

Painting Pointers - handy hints Spray Gun Trouble Shooting

Paint Faults Paint Stripping Painting Plastics Compressors - choice and use

More Hims, Tips IJnd Informarion Safety - see 'Sa fety Sense ' Identifying the paint to use - see Ch. 4 Pain ting : Part 2 Colour Codel - lee Ch. 4 Painting: Part 2 Daaling With Brush-p ainted Bodywork - including use of an isolator p.int- see Ch. 4 Palming: Part 2

78

•

• •• " • •• 79

91

17

94

• 102

Respraying a Rear Wing: 94- 102 2-pack paint. Iow-bake allen usage Ramolling dents Simple panel preparation, use of filler , masking off, using stopper Identifying the paint(Q use Brush-painted Bodywork: 102-105 How to Deal With It. (Cuning out cormsion, lelting- in and welding II repair patch. orbital sanding. rust killer use. spray painting with isolator),

More Hints, Tips and Information Safely - see ' Safety Sense' Rubbing down (flatting) - see Ch. 6 Repairs On A Shoestring (Cuning Out Rust. etc) Painting wi t h aerosol cans ｾｮ､＠ touching-i n scratChes - see Ch. 6 Repairs On A Shoestring (BodYWOfk Repair and Improvements From A Can) Polishing Faded Palnt- see Ch. 9 Accessories and ImprovementS Pinstriping and Decals - S88 Ch. 9 Accessories and ImprOllements

5

177

17

• • •• •

• •• •

172

178

27. 278

•• •

Hints, Tips Bnd Informa/ion

Safety - see 'Salely Sense'

17

Stripping and refitting doors, windows and sports car soil tops - see eh. 8 Doors, Windows and Soh Tops

eh. 5 Bodywork Repair.

'0 81 90

Ch. 4 Painting : Part 2

•

ｍｯＬｾ＠

75 75 75

Bits in the Gloss Coat! - don',

panic l

Spraying Qut of Doors - see eh. 6 Repairs On A Shoestring

Accident Repair wort; : 106-109 Assessing the damage Use 01 body repair jigs Using Body Filler 110 Using Body Solder 111 Body Fillings Removing Stubborn Fikings Ught Crash Repair - front end d amage: 121 - 126 Replacing bolt -on wing and fron t panel Removing dents Blending -in the edge of a sprayed panel Ught Crash Repair - side damage: 126- 132 Remolling dents Filling a door skin Fining a new sill Using a hydraulic body pusher Fi tting a Replacemen t 801ton Wing 133 RemOlling and Fining a Welded-on Wing: 136- 140 Cutting panelwork Cutting with o.y-acelylene Renewing a Door Skin 140 Using a DIY Patch- Panelrear lIalellClI, boot floor, front w ing 143 Bonnet/Front Damage Repair 14' Front Wing Damage Repair: 149- 152 Panel beating 80dy filler usage Spraying clear-()\ler-base pa int Old Timer Body Repairs 153 Adjustments - t ips on fitting-up panels and doors 154 Second-hand Parts: 156- 161 Sailiaging a panel Fining a saillage I o _. niO_· coolod 10< IOI'>g _t-liloo

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Sofl;"",,'" No. 10

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