Panel Patch Installation
- Make a paper or cardboard pattern the size and shape of the cutout hole in the panel.
- Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces.
- Using the pattern as a guide, cut the patch to size.
- Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout.
- Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole.
- Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout.
- Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side.
- Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper.
- Mix enough adhesive to cover one side of all support squares.
- Apply adhesive to cover one side of all support squares.
- Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares.
- Position patch in cutout against support squares and adjust patch until the gap is equal along all sides.
- Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch.
- Apply a coat of adhesive to the exposed ends of the support squares.
- Install screws to hold the patch to support squares. Tighten screws until patch surface is flush with panel surface.
- Allow adhesive to cure, and remove all screws.
- Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch. With compressed air, blow dust from around patch.
- Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch.
- Mix enough adhesive to cover the entire patch area.
- Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair.