1994 MAZDA MX-5 SECTION T

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 d Repair of Polypropylene Fascia Repair of polypropylene fascia having flaws that have reached the surface of the polypropylene and are too serious to be restored by the painting. I Hole Crack Flaw A - A' Section B - B' /a - c, Section D-D' Section @ Top coat layer O Primerlsurfacer layer @ Primer layer @ Polypropylene layer I 1. Cut the rough edges around the flaw with a knife to make it smooth. Sand the area with a sander to make an angle of about 45". A - A' B - B' Section D - D' Section ,,/Cut with knife / / / / Make angle with sander - / I L h, 45" - 45" angle necessary for deposit of polypropylene welding rod Gartner Banana

PLASTIC BODY PARTS 2. Weld damaged area For repair of a cracked area, melt the crack together a heat gun and a special attach- ment. - B' section Melt area with heat gun C - C' Attachment Section after melting For repair of a hole, degrease the area and apply aluminum tape on the reverse side of the damaged area. A - A' Section Degrease surface ~lumin;m tape 3. Melt the polypropylene welding rod with a heat gun and deposit it in the cracked area. B - B' C - C' Section Welding rod (Polypropylene) / - - (Polypropylene) Melt this area Note a) Heat the shaded area to melt it. b)Take care not to excessively melt the welding rod. If the part is welded with the welding rod melted like jelly, the welding strength will be lowered. c) Hold the heat gun 10-20mm (0.39-0.79 in) away from the part that will be welded. d)Do not move the welding rod until the welded part cools. A - A' Section Welding rod (Polypropylene) Welding rod (Polypropylene) / I TOP view Tape Gartner Banana

-pp - - ------ - - - - - - -~ I LAYOUT OF CONTENTS I DISPOSITION 7YPOGRAPHIOUE DE CONTENU I nlSPOSlClON DEL CONTENIDO / ANORDNUNG DES 1Nt1ALTS U.S.A. Catalog No. AU-NA04-03 a The followrng IS il tvpical exornplc of the layout of contents on Mazda m~crofrctlr :)arts ca1aIog Voicr trn cxe:nple typlquc de la disposition typc!yraphique de contenu clar~s les m:crofrctles de catalogue des pieces de Mazda El slgulentc es trn qeinplo ripico de la disposition dcl conten~rlo crl una microfrcha del catalogo de rur)ur!stos dt: Mazda. Folgcndos ist ein typlsct~es Ueispie! der Inhaltsariordnuny des t\'razcia.~41krof1~tie~Teiiekataloys. 0 Remark : Tho nems listed under@ nave been deletod from each fiche since Dec. '93 @ Lsywt of contents Disposition Typo 0 graphique de Contcnu Disposicibn del conten~do Anordnung Per I~ilidlr: r'ictorial lndex Index p3r Schdmas lndicc: Grdfico lllu~trisrler lndex Illustration & Text Il.ustrst~ons e* Texrrr . \lurtrt..ibn y 7'thtc Abbildung und Te:r @ . Master Section No. lndex . Indc