All repair and maintenance tasks shown should be done by professionals only. Please do not try this at home or if not qualified by professional education. Always follow car manufacturer's instructions. Limitation of liability.

Bonding of Laser Brazed Roofs

Replacing OEM-laser brazed roofs

Bonding applications in the automotive industry have increased significantly during recent years. Learn everything you need to know about roof repair in special laser brazed roofs, applying OEM-approved repair methods.

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In our instruction we show bonding of laser brazed roofs. There are various frame designs and repair methods for roof replacement. Here we only show the repair of the frame design shown above. Make sure to always follow the manufacturer's instructions.

Here are some frame designs. This step-by-step instruction shows only the repair of the laser brazed roof with the frame design C in pictures.

A, B, C Direct glazing bead as help for adjustment of roof to body
C, D Self-adjusting roofs

STEP 1

Surface Preparation

Grind bondlines to bare metal. Clean and pre-treat the bonding surface with TEROSON VR 20 using a lint-free cloth. Apply masking tape on the side rail and new roof.

STEP 2

Check new roof

Place the new roof in the cleaned body frame to make sure that it fits.

STEP 3

Mounting Aid I

If you work on bare metal, apply TEROSON PU 8519 P for surface preparation for the direct glazing dam / mounting aid.

STEP 4

Preparation of the cartridge

Open TEROSON EP 5055 or TEROSON EP 5065 cartridge (choose either product) and squeeze out small amount of material until both adhesive components run equally. Clean tip. Apply the mixing nozzle and discard the first 5 cm of the mixed adhesive.

STEP 5

Corrosion Protection

Apply adhesive to the new roof and the body frame. Spread adhesive with a spreader or brush. All bare metal areas should be covered with adhesive (roof and car body frame) for corrosion protection.

STEP 6

Anti flutter application

Apply TEROSON MS 222 to roof bows for anti flutter. Mount new roof within processing time of approx. 30 min. Alternatively, apply TEROSON PU 9161 AF after roof mounting. Neither product causes read-throughs.

STEP 7

Mounting Aid II

Apply a bead of TEROSON PU 8597 HMLC on the primed surface as a mounting aid parallel to the flange. Consider the processing time.

STEP 8

Adhesive Application

Apply a bead of TEROSON EP 5055 for bonding. Either to the new roof or to the body frame.

STEP 9

Assembly

Fit the new roof. If spotwelding is required, this work has to be done within 60 min. after product application.

STEP 10

Post-assembly

Form adhesive and remove excess product with TEROSON VR 20. Then remove masking tape.

STEP 11

Curing

Cure product at 23°C room temperature for 48 hours. Curing can be accelerated by heat with infrared (30 min. at 80°C object temperature) or heating pads.

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