1999 LAND ROVER DEFENDER Workshop Manual

77PANEL REPAIRS
12
SEALING AND CORROSION PROTECTION CAVITY WAX
Cavity Wax Injection
Box sections treated with cavity wax are shown in this
section. Repairs affecting these areas must include
re-treatment with an approved cavity wax, using the
access points illustrated. In addition, all interior
surfaces which have been disturbed during repairs
must be wax injected whether they have been treated
in production or not. This includes all box members,
cavities, door interiors etc. It is permissible to drill
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable zinc
rich primer, brushed with wax and then sealed with a
rubber grommet.
Prior to wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using a
compressed air supply.
Carry out wax injection after final paint operations.
During application, ensure that the wax covers all
flange and seam areas and that it is applied to all
repaired areas of both new and existing panels.
NOTE: Apply cavity wax AFTER the final
paint process and BEFORE refitting of any
trim components.It should also be noted that new panel assemblies and
body shells are supplied without wax injection
treatment which must be carried out after repairs.
Effective cavity wax protection is vital. Always observe
the following points:
Complete all finish paint operations before
wax application.
Clean body panel areas and blow-clean
cavities if necessary, before treatment.
Maintain a temperature of 18°C (64°F)
during application and drying.
Check the spray pattern of injection
equipment.
Mask off all areas not to be wax coated
and which could be contaminated by wax
overspray.
Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
Move door glasses to fully closed position
before treating door interiors.
Treat body areas normally covered by trim
before refitting items.
Check that body and door drain holes are
clear after the protective wax has dried.
Keep all equipment clean, especially wax
injection nozzles.
ProCarManuals.com

PANEL REPAIRS
13
SEALING AND CORROSION PROTECTION The following Illustrations show the treatment areas and Injection holes for Cavity Wax application.
All areas symmetrically opposite to those shown are also treated.
Bulkhead assembly
1
M77 2072A
B
A - A
B - B
2
A
A
B
Section A-A and B-B show application areas of cavity wax. Arrows 1 and 2 show application holes.
ProCarManuals.com

77PANEL REPAIRS
14
SEALING AND CORROSION PROTECTION ’B/C’post assembly
1
M77 2073A
AA
BB
A - AB - B
2
Section A-A shows application area of cavity wax for the’B/C’post. Arrow 1 shows application hole.
Section B-B shows application area of cavity wax for the’D’post. Arrow 2 shows application hole.
ProCarManuals.com

PANEL REPAIRS
15
SEALING AND CORROSION PROTECTION Front door
M77 2074A
B - B
2
2
2
2
1
A
B
B
A
2
A - A
Section A-A and B-B show application areas of cavity wax for the front door. Arrows 1 and 2 show the application
holes.
ProCarManuals.com

77PANEL REPAIRS
16
SEALING AND CORROSION PROTECTION Rear door
M77 2075A
B - B
1
A
B
B
A
222
2
A - A
Section A-A and B-B show application areas of cavity wax for the rear door. Arrows 1 and 2 show the application
holes.
ProCarManuals.com

PANEL REPAIRS
17
SEALING AND CORROSION PROTECTION SEALANTS AND ADHESIVES
Structural Adhesive
Metal-to-metal adhesive is applied to critical joint
areas during factory assembly. The material used is a
high-temperature, heat cured, nitrile phenolic which
serves both to bond two metal surfaces and also to
seal the joint against ingress of dust, water, petrol and
fumes. This material is not suited for service use, and
should be substituted in repair using a suitable
medium strength adhesive.
When separating a joint treated with metal-to-metaladhesive, to avoid distortion it is recommended that
the joint be gently heated until the bond weakens
sufficiently to permit panel separation.
NOTE: DO NOT carry out MIG welding on a
joint area which has been treated with
metal-to-metal adhesive until all traces of
adhesive have been removed.
The following Illustrations show the treatment areas
for Structural Adhesive.
All areas symmetrically opposite to those shown are
also treated.
Body side capping
Structural adhesive applied around body side lower fixing holes
ProCarManuals.com

77PANEL REPAIRS
18
SEALING AND CORROSION PROTECTION Seam Sealers
A heat cured, PVC Plastisol sealer is applied to joint
areas during factory assembly. This material is not
suitable for service use.
Carry out seam sealing after the application of primer
and before the surfacer and final paint coats. Ensure
that surfaces are first cleaned of all grease and oil.
Apply the sealer material to the joint as a bead, either
by hand or using an applicator gun. Where necessary,
brush sealer well into the joint and wipe smooth using
a cloth soaked with solvent such as Shell SBP3. This
will ensure an acceptable cosmetic finish.
Apply sealer to ALL accessible joints following repair
work. Be aware that damage to a vehicle can often
result in deflection to those areas of the body which
are remote from the impact. The sealers in these
areas can therefore be disturbed by subsequent
straightening and repair operations. Check joints in
the vicinity of the area undergoing repair for evidence
of cracked sealer, clean them out as required and
re-treat them with fresh sealer using the following
procedure:
Clean the affected joint or seam and
re-treat any exposed metal areas with a
suitable etch phosphate primer.
Treat affected area with an acid-etch
primer.
Apply appropriate seam sealer as
necessary.
Apply appropriate colour coat (and
underbody sealer as applicable).
Where joints are inaccessible following the
reassembly or fitment of components, ensure that a
paste-type sealer is applied to such joints. Certain
seams also become inaccessible after the completion
of panel repairs. In such instances the paint process
should be carried out and sealers applied before final
assembly.Provided access is adequate, apply the sealer to both
sides of the repair joint. Where access is limited to
one side only (e.g. box sections), inject the affected
box member with cavity wax.
CAUTION: ALWAYS deploy an extractor
unit to remove toxic fumes when using
oxy-acetylene equipment to remove panels
treated with wax and sealers.
The following Illustrations show the treatment areas
for Seam Sealing.
ProCarManuals.com

PANEL REPAIRS
19
SEALING AND CORROSION PROTECTION Seam sealing on bulkhead assembly - front view
All areas symmetrically opposite to those shown are also treated.
Seam sealing on bulkhead assembly - rear view
ProCarManuals.com