BASE COAT FLEET REPAIR PROCEDURE :

SUNFIRE 451 Field Repair Basecoat utilizes the same toners and similar mixing clears as used in

SUNFIRE 351 OE Basecoat. Refer to SUNFIRE 451 Basecoat Clearcoat Product Data Page for further product information.

Bare Surface Preparation

Bare Substrates*: Steel, Galvanized Steel, Aluminum or Fiberglass *Note: With the inconsistencies of substrates, consult your local SHERWIN-WILLIAMS Representative for system recommendations and substrate testing.

1) Solvent clean with SHER-WILL-CLEAN® Solvent Cleaner R7-K156 or AQUA-MATE® Low VOC Surface Cleaner W4-K157 and wipe dry with a clean, dry cloth.

2) Mechanically abrade all bare metal. For hot-rolled steel, a media blast is required to remove any surface impurities.

3) Solvent clean with SHER-WILL-CLEAN® R7-K156 or AQUA-MATE® Low VOC Surface Cleaner W4-K157, wipe dry with a clean, dry cloth. For hot-rolled steel, proceed to step #4.

4) Apply 2-3 medium coats of G.B.P.® Etching Filler E2-G980 or one double coat of CORROSION SHIELD™ E2-G973. Or treat bare steel areas with MET-L-ETCH™ Steel Cleaner W4-K288 followed by MET-L-Mate® Phosphate Conversion Coating W4-K289. Treat bare aluminum with DUAL-ETCH® Metal Cleaner and Conditioner W4-K263.

Pre-painted Surface Preparation

1) Wash surfaces with a mild detergent in hot water. Rinse well and wipe dry with clean, dry cloth.

2) Solvent clean with SHER-WILL-CLEAN® Solvent Cleaner R7-K156 or AQUA-MATE® Low VOC Surface Cleaner W4-K157 and wipe dry with a clean, dry cloth.

3) Grind off paint and remove all rust. Fill as needed using Sherwin-Williams NO-STAINTM Premium Light-Weight Body Filler D2-A136. Allow body filler to tack up and shape as needed.

4) Sand repair area and featheredge using 80, 180, 280 and finish with 320 grit treated sandpaper on a random orbital sander. Use SHER-WILL-CLEAN® Solvent Cleaner R7-K156 or AQUA-MATE® Low VOC Surface Cleaner W4-K157 to remove sanding residue before recoating.

5) Apply 2-3 single wet coats of G.B.P. Etching Filler E2-G980 or E2-G983 to bare metal and body filler to achieve 1.0 mil minimum. OR, treat bare steel areas with MET-L-ETCH Steel Cleaner W4-K288 followed by MET-L-MATE Phosphate Conversion Coating W4-K289. Treat bare aluminum with DUAL-ETCH Metal Cleaner and Conditioner W4-K263. (NOTE: Use W8-A2500 to meet California VOC compliant recommendations)

6) Apply ULTRA-FILL II Primer-Surfacer P6-H49, P6-A48 or COLOR-PRIME Tintable Primer-Surfacer P6-A47 as needed and block sand with 180 to 280 grit treated sandpaper.

7) Finish sand repair area with 320 grit treated sandpaper on a random orbital sander.

8) Prep entire blend area or panel by water sanding with 1000-1200 grit or scuff with a gray scuff pad and USP-90 Scuffing Gel.

9) Re-clean thoroughly with R7-K156 or W4-K157.

10) For larger repair areas use ULTRA-FILL II E6-H59, EPOXY PSE-4600 or PRIME-SHIELD E2-A820 for best results.

Mixing Procedures

Color Activation

Mix by volume, 5 parts SUNFIRE 451 Color with 2 part R7-K7210 Reducer and 1 part SUNFIRE Hardener V6-V769. Stir thoroughly and strain before use.

CUT-IN / BLENDING CLEAR Activation and Reduction

Mix by volume, 6 parts CC630 (or CC632) to 1 part CCH690 and 20 - 30 parts US-3. Stir thoroughly and strain before use. Use within 4 hours.

SUNFIRE BASECOAT BINDER Reduction

Mix by volume, 1 part V2-V109 basecoat binder and 1 part US-3 (or R7-K6202) reducer. Stir thoroughly and strain before use.
When using pressurized equipment for Full Panel or Larger Repairs, use the SUNFIRE 451 Basecoat Primary Color Formula.
When using conventional siphon feed or HVLP for Spot Repairs, use the alternate SUNFIRE 451 Basecoat formula. Check repair color for blendable match by spraying out a test panel and comparing to OE color prior to spraying actual repair. For metallics, if additional tinting is necessary 10-20% of the non-metallic toner can be added to achieve a blendable match. Whenever possible, set up entire panels or zones with break lines for blending and clearing out the entire panel. This will assist in achieving the best possible repairs. Only blend/melt clear into the existing finish if absolutely necessary.

Solid Colors

Use SUNFIRE 365 Basecoat if SUNFIRE 451 formula is not available. Mix SUNFIRE 365 according to data sheet.

1) Mask the adjacent panels or blend areas with masking paper. Only expose the repair areas

2) Adjust air pressure at the gun to 45 psi for siphon feed or pressure feed (adjust pot pressure to 5-10 psi). Use 20 psi for small repairs to minimize overspray.

3) Apply 2-3 medium wet coats at a gun distance of 8-10 inches; spray to hiding, allow each coat to become hand slick before applying the next coat. After hiding is achieved apply a low pressure mist (drop) coat at 25 psi at a gun distance of 10-12 inches to blend the basecoat into the OEM finish. For small repairs apply basecoat at 20 psi to minimize overspray; a low pressure drop coat is not required in this case

4) AIR DRY FOR 45 MIN. PRIOR TO CLEAR COATING.

Metallic or Mica Colors

Important: For best results set up 2 guns; 1 for SUNFIRE 451 Color and 1 for CUT-IN / BLENDING CLEAR.

1) Apply one medium/wet coat of CUT-IN / BLENDING CLEAR to the entire blend panel, using 25-30 psi for conventional spray gun and 6-7 psi air cap pressure with HVLP.

2) Immediately Apply SUNFIRE 451 Color over the repair area to achieve hiding. This will normally require 2-3 coats only. Allow approximately 5 min. flash between coats. After hiding is achieved, allow to flash 10-15 min.

3) Mix Pre-reduced SUNFIRE BASECOAT BINDER V2-V109 with ready-to-spray SUNFIRE 451 at a 1:1 ratio. Using a 25-30 psi, apply a mist coat over the entire repair area, blending or fading the color out into the blend panel/area.

4) Immediately after the mist coat is applied, melt the blend edge of basecoat with a light coat of the CUT- IN / BLENDING CLEAR used in step #3, also applying it out to the end of the blend panel. Follow the air pressure recommendations listed in step #3. Allow this to flash dull, 3-5 min. Then apply another light coat. At this point while wet, you can check the blend appearance. If necessary, additional color can be misted/blended out to correct any problems. Follow this additional color with light coats of the CUT-IN / BLENDING CLEAR as previously outlined. ALLOW THIS TO AIR DRY FOR 45 MIN. PRIOR TO CLEAR COATING.

Clearcoat Activation and Reduction

Clearcoat Option 1:
Mix by volume, 4 parts CC637 Clearcoat with 1 part Consolidated Reducer and 1 part UH-80 Hardener. Refer to the ULTRASOLV Reducer data sheet #2081 for proper temperature recommendations. Stir thoroughly and strain before use.

Apply 2 even medium coats of CC637 at 50 to 60 psi with a conventional spray gun or at 9 to 10 psi at the cap for an HVLP spray gun. Apply a maximum of two coats with a flash time of 2 to 5 minutes between coats. Follow the recommended drying schedule. If force drying the clear, use US-3, US-4, US-5, or US-6 for best results. Force dry for 20 minutes at140ºF. OR, force dry using IR for 10 minutes on low for flash and 20 minutes on high or until firm. Locate IR lamp no closer than 36 inches from the part. If force drying above 120ºF, DO NOT USE US-3.

Clearcoat Option 2:
Clearcoat with CC-350. Choose the proper reducer for the correct temperatures being sprayed (CCR-354, CCR-356, or CCR-358. CCR-352 may be used for air dry only). Mix by volume, 3 parts CC350 Clearcoat to 1 part Reducer to 1 part UH-100 hardener. Apply even wet coats using 55 to 60 psi at the gun or 9 to 10 psi when using an HVLP spray gun. Refer to Clearcoat Data Sheet for proper reducer selection and force dry recommendations. Apply 2 even medium coats of CC350 at 50 to 60 psi with a conventional spray gun or at 9 to 10 psi at the cap for an HVLP spray gun.
Apply a maximum of two coats with a flash time of 2 to 5 minutes between coats. Follow the recommended drying schedule. If force drying the clear, use CCR-354, CCR-356, CCR-358 according to lable directions for best results. CCR-352 is for AIR DRY ONLY.

Important Notes

Force dry for 20 minutes at 140ºF. OR, force dry using IR for 10 minutes on low for flash and 20 minutes on high or until firm. Locate IR lamp no closer than 36 inches from the part.

Application Equipment Recommendations

1) Allow clearcoat to cure. Sand with 1200 grit sandpaper followed by cross-sanding with 1500 grit sandpaper checking frequently with a rubber squeegee to ensure that the 1200 grit scratches are being removed.

2) Buff by machine with polishing pad using a quality microfinishing compound, follow with microfinishing glaze. For ultimate in appearance, hand glaze with a soft clean cloth.

Conv. Siphon 1.8 mm @ 45 - 55 PSI

Conv. Gravity 1.4 - 1.6 mm @ 45 - 55 PSI

Conv. Pressure 1.0 - 1.2 mm @ 8 -12 oz. / min. @ 45 - 55 PSI

HVLP Gravity 1.4 - 1.6 mm @ 45 - 55 PSI

HVLP Pressure 1.0 - 1.2 mm @ 8 - 12 oz. / min. @ 45 - 55 PSI





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