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Old 08-11-2012, 05:54 PM   #62 (permalink)
3-Wheeler
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Location: Southern WI
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AlienMobile - '00 Honda Insight
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Panel Maintenance

After two full years of being mounted on the car, the panels had to come off for a tire alignment.

Getting the fasteners out proved difficult, as many were rusted in and simply broke off when trying to be eased out with the screw driver.

The car went in for alignment, and after it came back, I had to drill out several of the broken fasteners.

Most of the panels looked pretty good, but several had some severe water damage and needed to be fixed.

The panel shown below is from the location right under the engine, and the section affected is right in front of the front tire, and gets quite a bit of water/snow flung from the front tire.

There are cut wood dowels that fasten to the underside of the grill fascia and hold the panel in that location. These wood dowels were complete saturated with water and had to be removed, and new one's embedded back into the foam in the same location.

This time, epoxy/micro balloons were mixed to form a slurry, that will hold and seal the wood dowels and not break down chemically from the water.



The same thing for the other front tire.



This part of the spat got hit with some debris on snow covered roads, and knocked out a chunk of foam, and was re-fiberglassed with several more layers to strengthen it up.



This tab was reinforced with the micro-slurry, since it had sustained water intrusion.



This portion of the panel has, what else, Bondo, and notice that it is simply flaking off.



The same thing again for this spot on the panel. It's pretty obvious that Bondo is not an item that should be used on epoxy/fiberglass composites. It just does not stick well enough long term.



Jim.
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Last edited by 3-Wheeler; 08-11-2012 at 06:01 PM..
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