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Panel Patch Installation

WARNING: This page is about a different car, the 2016 Jeep Wrangler and 2015 Jeep Wrangler. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Securing Support Squares To Body Panel
GC0080603Courtesy of CHRYSLER GROUP, LLC
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
  1. Make a paper or cardboard pattern the size and shape of the cutout hole in the panel.
  2. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces.
  3. Using the pattern as a guide, cut the patch to size.
  4. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout.
  5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole.
  6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout.
  7. 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.
  8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper.
  9. Mix enough adhesive to cover one side of all support squares.
  10. Apply adhesive to cover one side of all support squares.
  11. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares.
    Fig 2: Identifying Cutout And Support Squares
    GC0080604Courtesy of CHRYSLER GROUP, LLC
    1 - CUTOUT
    2 - SUPPORT SQUARES
  12. Position patch in cutout (1) against support squares (2) and adjust patch until the gap is equal along all sides.
  13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch.
    Fig 3: Applying Adhesive
    GC0080605Courtesy of CHRYSLER GROUP, LLC
    1 - APPLICATOR
    2 - SUPPORT SQUARES
    3 - ADHESIVE
  14. Apply a coat of adhesive (3) to the exposed ends of the support squares (2).
    Fig 4: Applying Coat Of Adhesive To Exposed Ends Of Support Squares
    GC0080606Courtesy of CHRYSLER GROUP, LLC
    1 - PATCH
    2 - GAP
  15. Install screws to hold the patch (1) to support squares. Tighten screws until patch surface is flush with panel surface.
  16. Allow adhesive to cure, and remove all screws.
    Fig 5: Grinding Surface
    GC0080607Courtesy of CHRYSLER GROUP, LLC
    1 - PATCH
    2 - GAP
    3 - DISC GRINDER
  17. Using a 125 mm (5 in.) 24 grit disc grinder (3), grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 75% -80% deep (original material thickness) path across the gaps (2) around the patch (1). With compressed air, blow dust from around patch.
    Fig 6: Covering Gaps With Mesh
    GC0080608Courtesy of CHRYSLER GROUP, LLC
    1 - GROUND DOWN AREA
    2 - PATCH
    3 - MESH
  18. Apply adhesive backed nylon mesh (drywall tape) over gaps around patch.
  19. Mix enough adhesive to cover the entire patch area.
    Fig 7: Applying Adhesive Over Mesh Around Patch
    GC0080609Courtesy of CHRYSLER GROUP, LLC
    1 - ADHESIVE
    2 - MESH
    3 - PATCH
    4 - SPREADER
  20. 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.
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