|
|
|
|
FORD'S THINK NEIGHBOR ELECTRIC VEHICLE & BODY PANEL REPAIR
 |
|
Figure 1–The Think Neighbor’s body panels are made of color-impregnated GE Geloy® thermoformed plastic. (Photo: courtesy of Ford Motor Company)
|
|
April 8, 2002 -Ford’s 2002 Think Neighbor is a low-speed, electric-powered vehicle that is slowly making its way onto the road in select markets, so collision repair facilities will need to know the proper repair procedures for this vehicle. This article will concentrate on the repair of the exterior body panels (see Figure 1).
The Think vehicle is interesting in its design in that the body panels are made from GE Geloy® thermoformed plastic that is color-impregnated. A top gel coat layer comprises approximately 20 percent of the part’s thickness. These panels, if damaged, cannot be refinished nor can they be welded or adhesively bonded.
 |
|
Figure 2–This fender has scratches that require repair.
|
|
Body panel repairs that can be made include light scuff and scratch repair (see Figure 2). The sample fender that we repaired had minor surface scratches. The top gel coat layer on the fender is approximately 4 mm thick, which is equivalent to about 157 mils. (see Figure 3). We attempted to remove scratches of different depths, and discovered that scratches that can safely be removed from the fender can only penetrate 5 to 6 mils into the top gel coat layer. If a scratch repair was attempted that went beyond this limit, the color and texture was altered. If this should happen, the part must be replaced. Keep in mind that each exterior body panel may vary in thickness.
|
 |
|
 |
|
Figure 3-The top gel coat layer on this fender is approximately 4 millimeters (top). The top gel coat layer can easily be seen on this sample panel piece (bottom).
|
|
 |
|
Figure 4–To repair the scratches on this fender, the proper tools and materials will be required.
|
|
|
What is unique about this material is that during scratch repairs the panel substrate itself is being repaired as compared to other plastics where the scratches are being removed from the clearcoat. Additionally, the use of P600 to P1000 grit to remove scratches is not common when performing clearcoat repairs. It is usually common to use P1000 to P2000 grit sandpaper to remove scratches before buffing to make detailing repairs to a clearcoat.
Repair Procedure
A rotary buffer, with 1,000 rpm capabilities, a finishing sander, an interface pad, P600 and P1000 grit sanding discs, cutting pad, polishing pad, compound, polish, and clean cloths are required to repair minor surface scratches (see Figure 4).
|
Click on the image to start the video to see an example of how to repair scratches in this material.
|
This video is [an error occurred while processing this directive]
Approximate video download times based on your connection speed:
56K-08:59
ISDN-03.41
Broadband-00:19
Video can be played partially while download continues.
Download this video ([an error occurred while processing this directive])
|
|
Repairing the scratches in a fender is simple enough to do and does not take too much time (see Video). The repair area will need to be cleaned with water. Do NOT use a solvent-based cleaner. Solvent will melt and degloss the plastic surface. Use the finishing sander, interface pad (see Figure 5), and P600 grit sanding disc to sand the surface. Sand using approximately 45 psi air pressure at the tool inlet. Do NOT sand at a high speed, which causes the sanding disc to load with dust and heat the surface. Proper sanding speed is based on cut and travel speed of the pad, and the downward pressure applied by the technician.
To clean the surface of the sanding pad, run the sander face at 90 degrees on the edge of a piece of cardboard. This will also help keep the sanding disc running cooler. Continue to sand the surface until the scratch can no longer be seen. Wipe the surface with a cloth. Then inspect the surface to make sure that the scratch has been removed.
 |
|
Figure 5–An interface sanding pad is used with a finishing sander, which has a shorter stroke, and is therefore less aggressive, than a regular dual-action (DA) sander.
|
|
Sand the surface with the P1000 grit sanding disc to remove the P600 grit sandscratches. Be attentive to the edges surrounding the scratch. Any P600 grit sandscratches left behind will be very hard to remove with buffing. Then wipe the surface clean.
Spread the compound on the area to be repaired. Install the cutting pad on the buffer and, depending on the buffer, set the buffer to the lowest speed on the dial, or do not exceed 1,000 rpm. It is best to buff between 500 and 1,000 rpm. Buffing at a high speed can heat and warp the material. Buff the repair area until the sandscratches disappear. A second and third application of the compound may be required.
Buff with the polishing pad and polish to restore the gloss. Follow by wiping the area clean with a soft cloth.
Conclusion
Ford’s Think Neighbor is the only production vehicle, at the time this article was written, that uses color-impregnated GE Geloy® thermoformed plastic for the exterior body panels. This type of color-impregnated material will no doubt be used on future production vehicles prompting the need for an awareness of proper repair procedures. Collision repair facilities need to be aware of what type of body panel they are working on. Is it color-impregnated, does it have a top gel coat layer, or is it a typical plastic body panel? These types of questions must be answered in order to determine the proper repair procedure.
|
|
|
 |
|
QuickTime and the QuickTime Logo are trademarks of Apple Computer, Inc., registered in the U.S. and other countries. The Get QuickTime Badge is a trademark of Apple Computer Inc., used with permission. |
|
|
|
|
|
