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Home >> Mini >> 2009 >> Cooper Works Clubman >> Repair and Diagnosis >> External Pages >> Different car >> Section 3411 (COLLISION - BODY PANEL REPAIR (F02) 760Li) >> Body Panel Repair General Information >> 41 00... Bonding Aluminium On Aluminium

41 00... Bonding Aluminium On Aluminium

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2015 BMW 760Li, 2014 BMW 760Li, 2013 BMW 760Li, 2012 BMW 760Li, and 2011 BMW 760Li. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Conform with safety precautions! See INFORMATION ON HAZARDS  and SAFETY AT WORK .

Overview of topics: 

  1. Equipment
  2. Preparing the surface
  3. Flame-coating
  4. Primer coat
  5. Bonding coat
  6. Hardening times
  7. Subsequent treatment
  1. 1.0 Equipment 
  2. 2.0 Surface preparation: 
    • For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire brush or special emery paper.
    • Clean adhesive areas with isopropanol, acetone or spirit.
    • Allow cleaned surfaces to dry for approx. 5 minutes.

      Adhesive areas must be completely dry.

    • The ridges on the repair parts (clamping pieces) approx. 0.5 mm high serve to orientate the minimum adhesive thickness. The ridges must not be ground off!
  3. 3.0 Flame-coating: 
    • Go over the adhesive areas slowly with the flame.
    • Avoid flaming with the blue part of the flame.
    • Condensation water appears on the area that is still uncoated. The condensation water in the line of the flame must evaporate completely.
    • Directly after flaming, coat the still hot adhesive areas (approx. 50°C) with primer.
  4. 4.0 Primer application: 
    • Apply the primer with a brush, cotton wadding or similar.
    • Allow the coated surfaces to dry for approx. 5 minutes.
  5. 5.0 Adhesive application: 
    • Processing temperature of glue cartridge 18 °C - -30 °C.
    • Object temperature, vehicle and new parts, min. 15°C.
    • Read the vehicle-specific repair instructions to determine the thickness and positioning of the adhesive bead.
    • After applying the adhesive, check whether an adhesive component has emerged at the back of the glue cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge.
    • Use a spatula to spread the adhesive over the adhesive area. Thickness of layer approx. 2 mm (dependent on adhesive gap).
    • Join components and secure in position.
    • Remove excess adhesive. Do not use solvent cleaning agents.
  6. 5.1 Bonding in conjunction with repair elements (expanding elements): 
    • Repair elements are special shaped parts to connect new parts with the body. E.g. partial replacement engine support.
    • The repair elements will spread when a special bolt is screwed in. The repair elements will thereby connect flush to the corresponding profile shape.
    • Ensure there is a sufficient gap between the adhesive and the threads for the expander screws (approx. 10-15 mm).
    • Spread adhesive over the repair element with a spatula up to the height of the ridges.
  7. 5.2 Bonding in conjunction with rivets: 
    • Make sure that the blind rivet wrench comes in as little contact with the adhesive as possible. There is a risk of damaging the exchangeable head of the rivet wrench due to emerged adhesive.
    • The standard punch rivets are always  replaced by blind rivets in conjunction with bonding.
    • The required strength of the connection is only achieved through a combination of bonding and riveting.
  8. 6.0 Hardening times: 
  9. 7.0 Subsequent treatment: 
    • Protect the repair area with cavity sealant.
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