1994 MAZDA MX-5 Workshop Manual

PLASTIC BODY PARTS Procedure for Repairing Urethane Fascia - To repair urethane fascia follow the procedures below. I Damaged paint Scratches or cracks in Fascia material not visible + Smooth damaged area material visible 1 Fa"ia I 1 4 Sand off old paint Urethane to make it Sand filler I hand paint around damaged area I Spray with primer or primer surfacer (Use primer for the heat-drying or primer surfacer for air-drying) Sand complete or partial surface I Replace the damaged fascia with a new one. I I v Sand complete surface of fascia + + + + Degrease 4 4 4 4 Spray with body color paint 4 4 4 4 Dry Gartner Banana

PLASTIC BODY PARTS Repair of Urethane Fascia This section describes repair of urethane fascia having flaws that have reached the surface of the urethane and that are too serious to be restored by painting only. Hole Crack Flaw A - A' Section - B' section C - C' D - D' Section - Top coat ............. 1. Smooth the rough edges around the hole or crack. Open a cracked section with a knife to make it wide enough to fill with filler. I Make round I A - A' Section - B' Section C - C' Gartner Banana

L PLASTIC BODY PARTS 2. Sand away the old paint around the damaged area [in the range of 30-35mm (1.18-1.38 in)] with #40-#80 sandpaper. 30-35mti-l A - *' Section 30-35mm (1.18-1.38 in) (1.18-1.38 in) - '' Section C - C' 30-35mm 30-35mm (1.18-1.38 in) (1.18-1.38 in) i D - D' Section 30-35rnm 30-35mrn (1.18-1.38 in) (1.18-1.38 in) Gartner Banana

PLASTIC BODY PARTS 3. Sand the urethane around the damaged area with #36-#50 sandpaper to make it taper. A - A' B - B' Section C - C' 15-20mm (0.59-0.79 in) ............... 15-20mm (0.59-0.79 in) 15-20mm (0.59-0.79 in) 7 w 4 t+- 15-20mm (0.59-0.79 in) D - D' Section 4. Degrease the repair area (the face and the back) with an appropriate degreasing agent. Cover the hole or crack with aluminum tape on the reverse side of the damaged area. A - A' B - 8' Section C - C' I Aluminum tape Do not use thinners or other chemicals as damage to the surface will result. I Gartner Banana

PLASTIC BODY PARTS L 5. Apply repairing filler A - A' B - B' Section Repair filler 7 C-C' / D - D' Section The repair filler is a two-part type filler composed of a main agent and a stiffening agent, and has the same flexibility as the urethane when hardened. In the case of air drying [18"C (65"F)], the part may be sanded after approx. 2 hrs. In the case of heat drying [50°C (122"F)], the part may be sanded after approx. 40 min. 6. Air dry or heat dry. Dry the applied repair filler completely. Drying time 7. After the repair filler has completely dried, and the repaired part with #I 20, #I80 and #240 sandpaper, respectively, to make it smooth. The effected part must not exceed 80°C (1 76"F), 120 or it may be deformed. ; go .- 3 - C 60 0 .- C h 3 0 30 0 A - A' B - B' Section , * n, --- - - : - - -- I I I ----- 1 -- - I I I --- --: --- I I I , - - - - - - - - - - -----; ----- L ----I I I I I I I I , I I I I - I 8 I I D - D' Section , 10 20 30 40 50 (50) (68) (86) (104) (122) Temperature "C (OF) Note If the repaired part is made concave, apply extra repair filler. Gartner Banana

PLASTIC BODY PARTS - 8. Sand the paint around the damaged area with #240 sandpaper to make it smooth. Degrease with appropriate A - A' degreasing agent I3 - 6' Section ,/ ,.. -. Caution Do not use thinners or other chemicals as damage to the surface will result. 9. Spray primer (heat drying) or primer surfacer (air drying) only on the effected area of the part. (Spot spraying) A - A' I3 - 6' Section C - C' D - D' Section 10. Dry the part. 1) Primer (Forced drying) Uniformly heat the repaired part. Heating condition: 80°C (176OF) (The temperature of the part) x 20 minutes Gartner Banana

PLASTIC BODY PARTS i- 2) Primer surfacer (Air drying) The time required for drying the applied part: Air drying [20° (68OF)l: about 8 hours Duration 11. Sand the area of the repair with #400-#600 sandpaper. If the surface of the urethane be comes visible, touch it up with primer or primer surfacer. 12. Degrease the part and spray on a top coat. Note Use paint suitable for urethane only. Normal body paint should not be applied to the flexible polyurethane fascia. If it is applied, it will not match the flexibility of the fascia causing the paint to crack or peel. Gartner Banana

PLASTIC BODY PARTS REPAIRING POLYPROPYLENE FASCIA d REPAIRABLE RANGE FOR POLYPROPYLENE FASCIA The three examples of damage shown below are considered repairable. Although a bumper which has been damaged greater than this could also be repaired, it should be replaced with a new one. Any larger repair would detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of workload. Allowable Repairs 1. A fascia with a hole less than 30mm (1.18 in) in diameter. 2. A fascia with a crack less than 150mm (5.90 in) in length. 3. A fascia with a crack less than 150mm (5.90 in) in length that is less than half of the width of the bumper. Gartner Banana