Vauxhall Workshop Service and Repair Manuals

Step C - Prepare Parts  

C1 - Remove and clean damaged components
•	Remove damaged front panelling (1).
•	Remove rough dirt, clean outside (2) and inside (3) with cloth.
C2 - Drill ends of cracks
Only for cracks and holes developing cracks.
•	Drill holes (4) at the ends of the cracks (approx. 4 mm/0.16 in. diameter), to prevent crack enlarging during repairs.
C3 - Prepare damaged area
•	Sand both sides of damaged area generously using sanding machine (P80) (5).
•	Mill visible area of damaged point (6, 7) to an approx. 45 ° angle (V-shape) using milling cutter or sanding machine.
•	Deburr edges of damaged area with knife, sand down again with sanding paper.

C4 - Blow off components
•	Blow off component with compressed air (1).
•	If necessary, remove remaining burrs with knife (2).
C5 - Prepare clamp
•	Prepare suitable clamp to hold damaged point.
	-	Wrap sheet metal plate (3) with contour foil from adhesive set or commercially available polyethylene (PE) foil (4).
		This foil is necessary to ensure that the sheet metal plate does not stick to the adhesive and can be removed again.
	-	Attach sheet metal plate to plastic component with vice-grip wrenches (5).
•	Remove clamp and lay aside.
C6 - Clean damaged area
•	Clean generous area of damage to remove oil, grease and dust.
•	Apply cleaner from adhesive set (6) on cloth.
•	Use cloth to clean damaged area, at the outside (7) and inside (8) sanded zones.