Page 137 of 659

CORVETTE BODY 1B-30
Fig*
66—Front
Body Construction
6. Panel - Front Fender Lower
1.
Panel - Hood
2.
Panel - Cowl Upper F. Front
3.
Panel - Front Fender Upper 7. Bonding Strip
4.
Bonding Strip - Front Fender 8. Panel - Radiator Grille
Upper to Lower
5.
Panel - Front Fender
Lower Rear
Lower
9. Panel - Radiator Grille Upper
- Lower Half
10.
Bonding Strip - Front
Fender Lower Front
to Rear
11.
Bonding Strip - Front Fender
Upper to Radiator Grille
Upper Panel
12.
Reinforcement - Front
Fender
13.
Bonding Strip - Front Fender
Upper Reinforcement
14.
Panel - Radiator Grille Upper -
Upper Half
contour. For deep filling and on vertical surfaces,
several layers may be used, each about 1/2" thick.
4.
Finish the repair by grinding, sanding and painting
in the usual manner, Figure 74.
RESIN KIT
The Resin Repair Kit, for major repairs, contains
resin, hardener, Thixatrope, fiberglass cloth, protecting
creams and mixing utensils. Repairs such as torn panels
and separated joints require the adhesive qualities of the
resin and the reinforcing qualities of the glass fibers.
The following procedure is basic for repairing any
plastic (fiberglass component or panel).
1.
Look for hidden damage. Apply pressure by hand
around the damaged area.
2.
Use paint remover and remove finish from around
damage area. Inspect area again for signs of other
damage.
3.
Grind or file the damaged area to form a "V" at
CHEVROLET CHASSIS SERVICE MANUAL
Page 138 of 659
CORVETTE BODY 1B-31
1
^JS^ST**-
Fig.
67—Center Body Construction
1.
Panel—Instrument
2.
Pad Assembly Instrument
Panel - Right
Hand
4.
Reinforcement -. Door
Upper Front
5. Panel - Door Inner
Upper
6. Reinforcement - Upper Rear
7. Cover - Front Access Hole
8. Reinforcement - Door Outer
Panel inner
9. Cover - Rear Access Hole
10.
Pillar Assembly - Door Lock
11.
Panel - Door Lower
Inner
12.
Sill - Door
13.
Molding - Rocker
14.
Panel - Side Door
Outer
15.
Panet - Door Hinge
Reinforcing
16.
Reinforcement Assembly
- Side Door Inner
17.
Bonding Strip - Side
Door Upper Bonding
18.
Pillar Panel - Hinge
19.
Hinge Assembly
20.
Pad Assembly Instrument
Panel - Left Hand
21.
Bracket - Radio Mounting
22.
Bracket - Clock Mounting
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-32
1.
Panel - Underbody
2.
Panel - Wheel Housing
Closing - Right Hand
3. Shield - Right Hand Splash
4.
Nut
5. Panel - Underbody Closing
Fig.
68—Underbody Construction
6. Shield - Left Hand Splash
7. Nut
8. Reinforcement - Body
Mounting
9. Panel - Wheel Housing Closing
- Left Hand
10.
Plate - Seat Belt Mounting
11.
Bracket - Center Cover
Mounting
12.
Plate - Transmission Control
Boot Retaining
the broken or cracked portion. Side of "V" should
have a shallow pitch for maximum bonding surface.
A belt sander with a vacuum attachment will mini-
mize the dust problem, Figure 75.
4.
If rear of damage is accessible, use a button-type
repair. Clean back of area to permit the use of
laminate (resin-saturated glass-cloth) on both sides
of damaged area.
5. Cut fiberglass cloth to size. Make certain a minimum
of five layers is cut for the average repair.
6. Mix resin and hardener, 1 part hardener to 4 parts
resin. Add Thixatrope to the mix to give the mix
body and reduce the "runniness" of the material.
CAUTION: Cleanliness is most important. Be
certain all containers are dry and clean and
the resin and hardener cans are kept closed
when not in use. Do not use waxed cups for
mixing and do not allow resin to enter hardener
can or vice versa.
7. Saturate layers of fiberglass (fig. 76). Place lami-
nate over damage area. Smooth out wrinkles and
make sure general contour of area is maintained,
Figure 77.
8. Apply heat to repair area. Heat lamps are recom-
mended, used at least 12" away from repair. Allow
.15 to 20 minutes curing time. Trim repair to shape
at gel stage.
9. After the repair is cured, grind, file or sand to
contour. Files other than body files may be more
suitable. A belt sander with a vacuum cleaner at-
tachment will minimize the dust problem. Feather
edge and finish sand.
NOTE:
After Resin Repair, small pits or ir-
• regularities may appear in finished surface.
Imperfections should be repaired using the
Plastic Solder Repair Kit.
SPECIFIC REPAIRS
Scratched Panels, Spot Refinishing
In many instances, a scratched panel will involve only
a paint refinishing job. Figure 78 shows the top of a
fender panel which has been scratched through to the
plastic.
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-33
Fig.
69~Bonding Strips - Roof Reinforcement
1.
Body Hinge Pillar - Right Hand
2.
Roof Panel Side Front - Right Hand
3. Roof Panel Side Rear - Right Hand
4.
Roof Panel Rear
5. Roof Panel Side Front - Left Hand
6. Roof Panel Side Rear - Left Hand
7. Roof Panel Front
8. Body Hinge Pillar - Left Hand
9. Windshield Lower Outer - Left Hand
10.
Windshield Lower Outer - Right Hand
1.
Remove all paint down to the plastic from the area
surrounding the scratch with Lacquer Removing
Solvent.
2.
Featheredge the repair area with No. 220 wet or
dry sandpaper and finish block sand with No. 320
wet or dry paper, Figure 79.
CAUTION: Do not sand too deeply into fiber-
glass mat. Should it be necessary to cut fairly
deep into the glass mat use the repair pro-
cedure suggested for dents and pits in plastic
panels.
3.
Clean up repair area Prep-Sol or its equivalent,
then finish the clean-up with a tack rag.
4.
Protect surrounding panels by masking before per-
forming paint refinishing operations. Use only non-
staining type masking tapes on Corvette plastic body.
5. Refinish panel as described in paint refinishing
portion of this manual.
Dents or Pits in Panels,. Cracks in Glaze Coat
Figure 80 shows a panel which has received a heavy
glancing blow, resulting in an indentation or large pit
in the panel. The following procedure is advised for a
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-34
1.
Panel - Roof
2.
Door Assembly - Fuel Tank Filler
3. Bezel - Fuel Tank Filler Door
4.
Panel - Body Rear Upper
- Right Hand
5. Panel - Body Rear Upper
- Left Hand
6. Frame - Rear Window Inner
7. Panel - Roof Inner Trim
8. Lid Assembly - Folding Top
Compartment
9. Hinge Assembly - Folding top Lid
- Right Hand
10.
Striker Plate Assembly - Right Hand
11.
Hinge Assembly - Folding Top Lid
- Left Hand
12.
Plate - Nut - Right Hand
13.
Extension - Body Rear Upper Panel
Fig.
70—Rear Body Construction
14.
Bonding Strip - Body Rear Upper
Panel to Quarter Panel
- Right Hand
15.
Support - Body Rear Upper Panel
16.
Panel - Body Lock - Right Hand
17.
Pane! - Body Lock Pillar - Right Hand
18.
Panel - Rear Quarter - Right Hand
19.
Shield Rear Quarter Splash
20.
Panel - Body Rear Upper
21.
Extension - Body Rear Upper Panel
Support - Right Hand
and Left Hand
22.
Bonding Strip - Body Rear Upper
Panel at Body Rear Lower
23.
Bonding Strip - Body Lower Panel
to Right Hand Quarter Panel
24.
Bonding Strip - Rear Filler Panel
Lower - Right Hand
25.
Panel - Rear Filler
26.
Bonding Strip - Rear Filler Panel
. Lower - Left Hand
27.
Bonding Strip -Body Lower Panel
to Left Quarter Panel
28.
Shield - Rear Quarter Splash
- Left Hand
29.
Bonding Strip - Body Rear
Upper Panel to Quarter
Panel - Left Hand
30.
Panel - Body Lock
31.
Panel - Body Lock Pillar
32.
Extension - Body Rear Upper Panel
33.
Panel - Rear Quarter - Left Hand
34.
Plate - Nut - Left Hand
35.
Striker Plate Assembly - Left Hand
36.
Body Rear Lower Panel
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-35
Fig.
71-Typical
1.
Door Sill to Underbody
2.
Dash Panel Extension
to Dash Panel
3. Grille Upper Panel to
Upper Panel Reinforce-
ment and Bonding Strip
4.
Rear Quarter Panel to
Underbody (Rocket)
5. Instrument Panel to
Door Hinge Pillar
Body Bonds
6. Rear Upper Panel Rear
Support Extension to
Rear Upper Panel Support
7. Body Rear Upper Extension
Panel and Rear Quarter
Panel to Bonding Strip
8. Body Rear Upper Panel
to Splash Shield
9. Rear Upper Panel Rear
Support Extension to Rear
Upper Panel Support
repair of this type of damage. Cracks in the glaze or
finish coat of plastic and paint may also use this
procedure.
NOTE:
This repair may be used wherever the
damage is not extensive and the plastic is not
pierced, but the damage area does require a
plastic build-up.
1.
Remove paint down to the plastic form area sur-
rounding the damage with Lacquer Removing Solvent,
or its equivalent.
2.
Scuff area surrounding damaged area to provide a
good bonding surface.
3.
Clean up work area with Prep-Sol then use tack
rag for finish clean-up.
4.
Use the Plastic Solder Repair (previously described)
to fill the imperfections.
5. Feather sand damaged area with No. 220 sandpaper
and finish sand with No. 320.
6. Prepare repair area for paint refinishing operatiou
Fig.
72—Mixing Plastic Solder Material
Cracked Panels
NOTE:
For best results, temperature should be
at least 70o-75°F.
1.
In the case of a cracked panel, such as shown in
Figure 81 cut along the break line with a hacksaw
blade and remove broken portion of the panel.
2.
Remove the paint down to the plastic from both
portions of the panel with a Lacquer Remover or
its equivalent.
3.
Remove dirt and deadener thoroughly, back ap-
proximately 2 to 3 inches from the fracture, on
Fig.
73—Applying Plastic Solder
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-36
Fig.
74-Finishing Plastic Solder Repair
Fig.
77—Applying Laminate to Body
Fig.
75—Grinding "V" at Damaged Area
pig.
76—Applying Resin Mixture to Fiber Glass
the under side of both portions of the panel. Also,
remove paint and scuff area clean to provide a
good bonding surface.
Remove all cracked and fractured material along
the break: Bevel the attaching edges of the panels
at approximately a 30° angle with a file or grinder
and scuff plastic surfaces along edges of break.
Fig.
78—Typical Scratched Panel
Fig. 79—Repair Area Finish Sanded
NOTE:
Mask surrounding panels using a non-
staining masking tape.
CHEVROLET CHASSIS SERVICE MANUAL
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CORVETTE BODY 1B-37
Fig.
80—Typical Pitted Panel
5. Use "C" clamps to align panel portions allowing
approximately 1/8" between the panels or as neces-
sary to provide proper alignment of panels, Figure
82.
6. Cut two pieces of woven glass fiber cloth for backup
of sufficient size to overlap the fracture by approxi-
mately two inches.
7. Clean up repair area with Prep-Sol, then use tack
rag for finish cleanup.
8. Use the Resin Repair Procedure previously
described.
NOTE:
In some cases it may be desirous to
provide additional reinforcements along a frac-
Fig.
81—Typical Cracked Panel
Fig.
82—Cracked Panel Preparation
ture. This may be accomplished by placing
glass cloth strips in the panel break before
applying the plastic mixture.
Fractured Panels
Sometimes damage will occur to panels where the
underside is inaccessible or for reasons of panel con-
tour it is impractical to use back plies of fiberglass
cloth. The following repair operations are typical of
this type of damage.
1.
Prepare the damaged area by grinding or filing all
cracked and splintered material away from the
fracture.
2.
Bevel the edge of the fracture at approximately a
20° angle.
3.
Remove paint from area surrounding fracture with
Lacquer Solvent, or its equivalent.
4.
Scuff surface to provide a good bonding surface.
Then, clean up area with Prep-Sol and wipe dry.
5. Protect adjacent panels by masking, use non-staining
masking tape.
6. Cut a strip of fiberglass cloth of sufficient size, so
the fracture will be lapped from 1 to 2 inches on all
sides.
7. Prepare plastic mixture in an unwaxed paper cup.
(See Resin Repair Kit procedure.)
8. Impregnate glass fiber cloth by brushing or dipping
in plastic mixture. Squeeze excess mixture from
cloth.
NOTE:
Avoid over-rich plastic areas in the
glass cloth, as the strength of the patch is
directly proportional to the glass content of
the patch.
9. Position plastic impregnated fiberglass over the
fracture on the exterior of the panel, lap the break
by 1 to 2 inches, and depress into fracture.
10.
Carefully work excess plastic out of woven glass
by "squeegeeing" from the center of the break
outward.
NOTE:
Hold woven glass in place until plastic
resin "gels" with Saranwrap or some similar
material.
CHEVROLET CHASSIS SERVICE MANUAL