41 00... Information On Metal Filler

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IMPORTANT: Note the following information before starting to apply metal filler!

Country-specific safety and industrial safety regulations
Material safety data sheet of manufacturer
Processing instructions on the packaging

Storage:

Dry at 15°C to 25 °C.

Shelf life:

The packaging is marked with a date.

Do not use the metal filler after this date.

Surface pre-treatment:

Grind surface to a metallic bright-finish. The surface must be clean, dry and free from grease.

Clean the surface with a cleaning agent R1 and let it vent for 2-3 minutes.

Processing:

The working temperature of the metal filler must be at least 18°C.

Fig 1: Identifying Metal Filler

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The mixture ratio refers to the volume.

Mix metal filler in mixture ratio of 5:2. Mix components thoroughly and free of pores.

IMPORTANT: Do not stir components. Danger of air pockets in metal filler!

Working life of the metal filler is approx. 45 minutes.

Applying filler:

Apply pressure to apply a thin layer of metal filler. Carefully coat all edges in gaps with filler.

Then fill gap completely with filler. Apply filler with about 30% excess because the filler will significantly shrink during hardening. A second application of metal filler is not possible due to poor adhesion.

IMPORTANT: Use a narrow spatula to fill the gaps. Apply the filler in one draw if possible. Danger of formation of pores in gaps!

No restrictions related to the layer thickness.

Hardening time:

The metal filler must be hardened using a short-wave infrared heater.

10 minutes at 50 °C - pre-hardening (avoid formation of bubbles/blisters and pores)
10 minutes at 75 °C - 1st stage hardening
10 minutes at 85 °C - 2nd stage hardening (avoid material shrinkage)

IMPORTANT: In the first 10 minutes, the temperature of 50°C may not be exceeded. In contrast, a temperature that is too low may be equalized by extending the time.

NOTE: When the heater is used for the first time, the distances that match the temperature must be determined.
Switch the heater on and change the distance until the surface temperature of the metal filler no longer changes for a period of 2 minutes. Measure the temperature with a temperature gauge. When optical temperature gauges are used (Epsilon value 0.92-0.95), the heater must be switched off briefly during the measurement. Record the measurement

Post-processing

WARNING: When grinding, wear a fine dust mask with particulate filter P2-P3!

After cooling, the metal filler can be machined.

Pores and faulty spots that become visible after grinding the surface must be closed with polyester filler (BMW Color system).

Special procedure for pores:

Use a Ø4.2mm drill. Turn the drill by hand to expand the pores in v shape. by t

Fill cavities with polyester filler.

Paintwork:

Perform paintwork according to the specifications in the painting handbook.

IMPORTANT: When using temperature-controlled infrared radiators, damage to adhesive bonds, paint and vehicle components can occur when drying spatula and filler.
The temperature sensors in the infrared radiator only operate reliably on large, even surfaces.
On small surfaces such as C-pillars or sills, often only a colder, adjacent area is measured.
This leads to actual surface temperatures of up to 130°C, even if only 70°C is set on the infrared radiator.
When the rear side walls are partially replaced by bonding and riveting, these high temperatures can lead to a visible pattern in the area of the joint.

Remedy:

Check the surface temperatures on small component surfaces during the drying process with an external temperature sensor.

The general rule is: The surface temperatures must not exceed 85°C.

Metal filler disposal:

Hardened metal filler is disposed of as normal waste.

Empty packaging is disposed of as normal waste.

Non-hardened metal filler and mixtures of metal filler with solvent and the like must be disposed of as hazardous waste.

These regulations apply to the Federal Republic of Germany .

For other countries, comply with the (possibly differing) nationally applicable regulations .