C 2500 Truck 2WD V8-454 7.4L (1988)
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Remove paint down to bare metal, approximately 1/2", where the front panel fits into the side panel as shown in Figure No. 1.
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Isolate the repair area by draping a drop cloth over the surrounding finished panels and glass to prevent accidental weld splatter.
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To weld the two panels, use a mig welder with 75% argon, 25% CO(2) or 100% CO(2) shielding gas and E70S3 wire (.035" or .045" diameter).
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Weld a 25 mm (1 inch) bead securing the front panel to the side panel (Figure No. 1). It may be necessary to hold these panels together with a "C"
clamp to get a good fit.
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Grind the welds flush.
FIGURE NO. 2
SPOT REPAIR USING URETHANE CLEAR COAT, FIGURE NO. 2
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Clean involved surfaces with a grease and wax remover (Dupont 3812S enamel reducer or equivalent).
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Feather edge the paint using standard paint preparation procedure.
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Metal prep the bare metal thoroughly (Dupont 5717 metal conditioner or equivalent).
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Mask off the surrounding area and spray on an acrylic primer (Dupont Variprime 615S/616S or equivalent).
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Apply a primer surfacer (Dupont 1315 or equivalent).
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Sand primer with 360 grit dry followed by 400 grit dry. Apply sealer (Dupont Velvaseal 1984S, 1985S, and 1986S or equivalents).
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Apply a paint adhesion promoter and allow to dry (Dupont 222S or equivalent).
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Apply base color coat per label direction for spot repair. Apply urethane clear coat (Dupont 1080S clear urethane, 1082S activator, and 1085S
reducer or equivalents) beyond base color coat but within the area of the adhesion promoter. Allow to dry overnight and compound.
PICKUP BOX REINSTALLATION
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Reinstall box to frame rails. Torque bolts to 70 N-m (52 lb. ft.).
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Reconnect wiring harness and ground strap.
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Reinstall and tighten the fuel filler tube to the side panel.
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Reconnect the negative battery cable.
Labor Op T7390 should be used when performing this procedure. Total time to perform this procedure is 2.6 hours. This time includes:
1.3 hours to make the repair
