GENERAL GUIDELINES FOR THE APPLICATION OF TECTYL AUTO/TRUCK/TRAILER RUSTPROOFING COMPOUNDS

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Number 17 GENERAL GUIDELINES FOR THE APPLICATION OF TECTYL AUTO/TRUCK/TRAILER RUSTPROOFING COMPOUNDS A. Equipment 1) Airless type spray equipment, designed for fluid pressure atomization.

1 Number 17 GENERAL GUIDELINES FOR THE APPLICATION OF TECTYL AUTO/TRUCK/TRAILER RUSTPROOFING COMPOUNDS A. Equipment 1) Airless type spray equipment, designed for fluid pressure atomization. The spray gun shall spray materials on the vertical, horizontal, overhead, or intermediate without abnormal fatigue to the operator. Material passages shall be adequate for material demand required for spraying with a minimum drop in pressure. The gun shall consist essentially of a body, necessary parts for the assembly of a nozzle, material valve, filter, connection, and a trigger. 2) The spray gun shall be equipped with a reversible self-cleaning adapter and a tungsten carbide spray nozzle or tip having an equivalent orifice size of to inch, designed to produce a fan-shaped pattern. 3) Series of wands or applicators capable of operating through 3/8" or 1/2" access holes. Applicators shall be capable of coating a full 360 degrees at right angles to the applicator with sufficient forward and backward throw for adequate coverage. 4) Accessories: Hole saw or drill for 1/2" hole. Plastic or rubber hole plugs. Magnet for holding protective paper over fender well, rocker panels, etc., when spraying from underside toward the outside. 5) Automotive and industrial airless spray equipment, spray wands, and accessories are manufactured by Alemite, Aro, Binks, Graco, and others. 6) Warning: Because airless spray units develop extremely high pressures, severe injury may result from any skin penetration. Never leave gun unattended without releasing pressure and engaging trigger lock. Always follow the manufacturer's recommendations for maximum pressures and operating instructions. The information contained herein is correct to the best of our knowledge. The recommendations or suggestions contained in this bulletin are made without guarantee or representation as to results. We suggest that you evaluate these recommendations and suggestions in your own laboratory prior to use. Our responsibility for claims arising from breach of warranty, negligence, or otherwise is limited to the purchase price of the material. Freedom to use any patent owned by Daubert Chemical Company, Inc. or others is not to be inferred from any statement contained herein. DCC 5/04

2 Technical Bulletin 17 Page 2 B. Cleaning Procedure The purpose of this suggested cleaning procedure is to describe the method and areas of the vehicle involved. The various designs of vehicle bodies and understructures make a rigid procedure impractical. Experience with the various types of vehicles will determine the best procedure for a particular vehicle. The surface preparation of the area to be treated is very important, since it has a direct bearing on the useful life of the coating. The following procedures are suggested. 1) Refer to applicable Material Safety Data Sheet to determine proper safety protection equipment before implementation of this procedure. 2) Move vehicle into position on lift (if lift is needed). 3) Close all vehicle windows, vents, and doors. 4) Raise vehicle to effective working level and remove wheels. 5) Cover disc brakes or drums and brake plate assembly with plastic or suitable covers. 6) Mechanically remove the heavy accumulation of dirt by using wire brush, putty knife, rubber hammer, or improvised tools. It is suggested that the cleaning of the vehicle commence from the front, working toward the rear. This will include the front splash panel, headlight area, front fenders, panels and supporting members, fender beads, floor pan, rocker panels, quarter panels, gasoline tank, tail and back-up light area, and rear splash panel. Remove heavy deposits of rust, loose undercoating, mud, gravel, and foreign material, paying particular attention to seams, welds, and corners. 7) Steam clean the underside of the vehicle. Operator shall wear protective clothing while steam cleaning (face shield, rubber apron, rubber gloves, and boots). Equipment subject to damage shall be shielded, and personnel are instructed never to direct cleaning jet at a critical area. 8) In case of new vehicles where limited driving has produced no appreciable road film, steam cleaning may be eliminated. 9) Rinse all steam cleaned areas with hot water. 10) Check drain holes to insure that they are open and water is draining freely. 11) After cleaning the vehicle, dry with either compressed air or heat lamps. If compressed air is used, air line shall be equipped with oil and water separators. 12) Vehicles shall be lowered to effective working level to remove covers and replace wheels. 13) Lower vehicle to floor and put aside to dry before applying protective coating. The next vehicle may be cleaned during this time.

3 Technical Bulletin 17 Page 3 C. Application of Tectyl Corrosion Preventive (automobiles) This application procedure is recommended in order to indicate the method of coating and the areas of the vehicle which are involved. Particular attention must be given to those sections of a vehicle that are most susceptible to corrosion, such as seams, welds, and corners. The various designs of vehicle bodies and understructures make a rigid procedure impractical. Experience with the various types of vehicles will determine the best procedure for a particular vehicle. This application should be performed at a location where mechanical dilution ventilation is present. The following procedures are recommended; however, the sequence of the steps may be altered to facilitate application. 1) Refer to applicable Material Safety Data Sheet to determine proper safety protection equipment before implementation of this procedure. 2) Move vehicle into position on lift. 3) Close all vehicle windows, vents, and doors. 4) Raise vehicle to effective working level of underside. 5) Apply the corrosion preventive compound by means of an airless type spray gun (see Section A). Accessory equipment such as wands or applicators with spray nozzles shall be used to apply the coating. Adjust the air pressure to provide the optimum coating. Figure 1 shows the areas of a passenger vehicle which are to be coated. It is understood that areas on both sides of the vehicle are included as applicable. Care shall be taken that the coating does not interfere with any mechanical or electrical component considered part of the vehicle. 6) Splash panel, front: Apply the coating with the fan pattern spray nozzle, paying particular attention to the seams, welds, and corners (this applies to all areas). The use of a reversible, self-cleaning nozzle may be advantageous in this application. 7) Headlight areas: Some vehicles may be so constructed that access to this area may be easier from above when the vehicle is on the floor. In some cases, access holes may be present or it may be necessary to remove the headlight. A short, curved wand may be used to advantage in this application. 8) Front fenders: Apply the coating to the fender well, fender bead, heavy splash area, baffles, and supporting members with the reversible self-cleaning spray nozzle. The short, curved wand may be used to spray the fender beads. 9) Rocker panels: On vehicles with access holes at each end, remove plugs and insert long straight wand as far as it will go. Spray continuously as the wand is withdrawn. Replace plugs; if not vented, wait until compound is dry. On vehicles with openings on the bottom of the rocker panels (Figure 2), enlarge the opening with a drift, insert short, curved wand, and spray in the same manner. If access cannot be gained by either of the above mentioned ways, drill three 1/2" holes in the bottoms of the panels and coat the interiors using a short, curved wand. Caution: Always punch a pilot hole before using electric drill. Check drain holes when coating has been completed to be sure they are open.

4 Technical Bulletin 17 Page 4 10) Quarter panels: Access to this area may be through an inspection plug near the bottom of the panel. Care must be taken as this may be an open area, and excessive spraying could result in material penetrating the truck areas. On some vehicles, this area may be treated from inside the trunk. In other cases, 1/2" holes may need to be drilled in the rear door pillar, high enough to clear the inner wheel housing. This hole should be located where the two panels diverge enough to provide room to insert the short, curved wand. Plug holes when completed. 11) Rear fenders: Treat the same as front fenders. Access to part of the rear fender may be possible through the trunk when the vehicle is on the floor. Be sure to coat the fender bead. 12) Tail and back-up light area: If this area is not accessible from underneath, it may be reached through the trunk when the vehicle is on the floor. On some vehicles, it may be necessary to remove the tail light. 13) Floor pan: Spray from front fenders back, using reversible, self-cleaning spray nozzle. Do not apply corrosion preventive coating to engine, oil pan, transmission, drive shaft, shock absorbers, axle bumper blocks, steering linkage, muffler, tail pipe, brake drums, brake backing plates, parking brake linkage, or gas tank vent tube. 14) Structural members: In a unitized or semi-unitized body, boxed-frame members are usually used. These areas should be thoroughly treated, inside and out, due to their contact with the body surface. Small but similar members welded to the floor pan should also be treated inside and out. Access to these areas may be gained through gauge and drain holes already present. A short, curved wand should be used for spraying the inside of these areas. 15) Gas tank: Apply coating to all exterior surfaces of gas tank. 16) Rear splash panel: Treat in the same manner as the front splash panel. 17) Inspect the underside of the vehicle to be sure all areas accessible from the underside have been properly treated. Check all inspection holes and drilled holes to be sure all plugs have been installed. 18) Lower vehicles to floor for remainder of the treatment. 19) Center door post: It may be necessary to drill a 1/2" hole in post not more than 8" up from the rocker panel. If door post is concealed when the doors are closed, the hole may be made on the outside surface. If not concealed, the holes should be made from the back side, so that the hole will not show. Insert short, curved wand in a downward directions and spray as shown in Figure 3. 20) Front door pillar: Treatment of the front door pillar may be possible through the door hinge opening. If not, drill a 1/2" hole approximately 8" from the bottom of the pillar. Insert a short, curved wand in a downward direction. This opening, in some cases, will provide access to the area behind the front fender and baffle. 21) Rear door pillar: If this area is not accessible from the trunk, drill a 1/2" hole in a non-critical structural area of the post. The hole should be located where the two panels diverge enough to provide room to insert the short, curved wand in a downward direction.

5 Technical Bulletin 17 Page 5 22) Front and rear doors: On some vehicles, plugged inspection holes can be used. If none are available, 1/2" holes must be drilled. Check drain holes in bottom edge of door to be sure water has drained from door. Holes should be located in each door end panel approximately 6 to 8" from the bottom as shown in Figure 4. Insert long, straight wand to treat the lower door panel area. Direct spray downward to prevent compound from reaching window regulator and to insure complete coverage of the critical areas inside the door. Plug all holes. 23) Check drain holes to be sure they are open. The following alternate method may be used for treating the doors. If the door upholstery is clipped on, loosen it from the door and use the short, curved wand to spray the lower 6 to 8" of the door. 24) Truck lid lower rear bead: Insert short curved wand through the existing holes in the trunk lid and spray. 25) Tailgate of station wagons: If holes are not available, drill a 1/2" hole in each side of the tailgate 6 to 8" from the bottom. Insert long, straight wand and spray the bottom area of the tailgate. Keep coating off window track and operating mechanism. As an alternate method, remove the inspection plate on the tailgate. D. Application of Tectyl Corrosion Preventive (light trucks) Light trucks are treated in a manner very similar to automobiles (See Figures 5 and 6). However, certain differences in body construction create additional points which require attention. In addition to the applicable areas in Section C, the following areas in light trucks shall be treated with corrosion preventive compound. 1) Doors: Many will have a removable metal access plate in the inner panel. This opening provides a means for spraying the inside of the door so that no holes need be drilled. Be sure the metal access plate is sealed when reinstalled to prevent rain from leaking through the door. 2) Rear doors: Spray compound into lower portion of rear doors. If holes are not available, drill a 1/2" hole in each vertical edge of the door and coat the lower portion of the door. 3) Inner panels: The inner panels separate the cargo compartment from the outside of the truck, providing a double-wall structure. If the inner panels do not extend to the full height of the body, spray the compound from the top edge downward. In some cases, 1/2" holes must be drilled 6 to 8" from the bottom of the inner panel between all vertical braces. Insert a short curved wand and spray the lower portion of this area. 4) Rear body skirt: Spray this area from underneath. Examine this area for hollow sections which need to be coated on the inside. In the case of vehicles which have the spare tire mounted in this area, be sure to remove the tire before spraying the area. Remove any compound that may come in contact with the tire.

6 Technical Bulletin 17 Page 6 E. Application of Tectyl Corrosion Preventive (truck cabs) Truck cabs are treated in a manner very similar to light trucks (See Figure 7). 1) Spray inside of all enclosed areas of roof, roof supports, roof drip rail, and roof shelf, including all boxed-in areas of roof overhang. Complete rear panel of cab from pillar to pillar, bottom to top, inside and out. Rear roof pillars complete inner surfaces to roof trough and from bottom of rear window line down to floor. F. Application of Tectyl Corrosion Preventive (trailers) Trailers are treated in a manner similar to light trucks. In addition to the areas shown in Figure 8, the enclosed areas of the upper coupler should be coated. 1) Insert flexible wand extension as far as it will go into the "D" holes of the upper coupler, making certain that the wand has not been reversed by some obstruction. Spray continuously as the wand is withdrawn at moderate speed. Experience will soon indicate proper withdrawal rate. If there are internal sections which are not accessible through the "D" holes, small holes (approximately 1/2") can be drilled after center punching to gain entrance. G. After application of Tectyl Corrosion Preventive (all vehicles) 1) Drilled holes and inspection holes: After application and drying, all holes shall be closed with plastic or rubber plugs, which are not softened or affected by the compound used in treating the vehicle. Drain holes shall remain open. 2) Workmanship: The coating shall be applied evenly with no running, sagging, or excessive build-up. Any overspray or material on body finish, trim, windows, or upholstery shall be removed as follows: a) Body finish, trim, and windows: Remove any compound which has adhered to the body finish, chrome trim, or windows with a clean cloth and a solvent such as naphtha, which is known to have no adverse effect on body finish. b) Upholstery: Remove with a clean cloth and a minimum amount of solvent, such as naphtha, any compound which may have been deposited on the upholstery. Excess solvent may damage rubber padding and upholstery adhesives. NOTE: Dispose of all unused Tectyl product and all residue from cleaning procedures in accordance with all applicable local, state, and federal regulations.

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Restoring Corrosion Protection Following Repair

SECTION 501-35: Body Repairs 2009 Mustang Workshop Manual GENERAL PROCEDURES Procedure revision date: 09/05/2008 Restoring Corrosion Protection Following Repair Special Tool(s) Rust Inhibitor Installation