51 48... Notes for bonding sound insulation (SI), doors

Special tools required: 

• 51 0 300

Attention! 

Do not yank at the sound insulation (risk of damage).

General: 

Sound insulation is bonded to the inner door panel.

Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.

On-the-job safety: 

When working with bonding products (adhesive, cleaning agent, etc.):

• Wear safety goggles, protective gloves and if necessary an apron.
• Ensure the area is well ventilated.
• Change work clothing contaminated with adhesive immediately.
• Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing on hand).
• Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams.
• Always keep an eye douche on hand, change the water regularly (once a month).
• Comply with the relevant safety regulations.

Handling adhesive area on inner door panel: 

Adhesive

1. Butyl bead applied to sound insulation with protective film
2. Butyl mini-round profile ø 4 mm from the roller
3. Butyl round profile ø 6 mm from the roller

Cleaning

1. CLEANING AGENTR2 

   Under no circumstances: paint thinning

2. Carry out bonding only after an air drying time ≥ 1 min. Air drying time may be omitted if the entire bonding surface is wiped with a dry cloth
3. After cleaning, the bonding surface may not be touched with hands or fouled again

Repair in area of sound insulation, door: 

Repair in the event of damaged sound insulation or leakage

• Cut the butyl rope between the sound insulation and the inner door panel with a sharp knife
• After the repair is finished, position a new butyl rope ø 4 mm directly on the original adhesive bead
• Heat the butyl bead with a standard hot air blower until the butyl rope strings when touched slightly. Do not damage the sound insulation in the process
• Press on with special tool 51 0 300 . Perform this work extremely carefully because the increased amount of adhesive requires contact pressure of ≥ 20 N/cm² (compared to firm thumb pressure ~ 30 N/cm² )
• Visually check the adhesive bead and its compression (no capillaries or broken adhesive bead permitted)
• In the cases mentioned, the complete sound insulation must be replaced. After removing the sound insulation, removal all butyl remnants from the inner door panel. Apply 6 mm ø butyl rope to new sound insulation
• Press on with special tool 51 0 300 . Contact pressure ≥ 20 N/cm² (compare to firm thumb pressure ~ 30 N/cm² )

The sound insulation must be bonded watertight below the door lock: 

• Flat bonding surface required all round.
• No bonding in the event of moisture (e.g. condensation, etc.).
• Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.).
• Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
• The sound insulation must be attached with positional accuracy to the inner door panel because it will no longer be possible to change the position without damaging the butyl bead.
• With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).

Expiry date of adhesive: 

24 months, see label on packaging.

Disposal of the cleaning cloth: 

Adhesive, cleaning cloths, and cleaning agent residues are hazardous waste.