VW Golf manuals

Volkswagen Golf Service & Repair Manual: 2-pack diamond aluminium filler

Designation:
  2-pack diamond aluminium filler, powder -DA 004 200 A2-
  2-pack diamond aluminium filler, hardener -DA 004 201 A1-
  2-pack diamond aluminium filler, hardener -DA 004 211 A1-
Issue 09.2014
Product description
This filler is an all-purpose polyester filler especially suitable for repair of sheet aluminium.
It is designed for use in automobile repairs.
This filler is easy to spread and sand, and has great mechanical and thermal stability.
  Note
If the temperature is above 30 °C or relative humidity is above 80%, hardener -DA 004 211 A1- must be used.
Technical data sheet
Substrate
Suitable substrates:
  Aluminium
   
Substrate pre-treatment:
 

2-pack diamond aluminium filler

–  Carefully remove any grease and sand surface. The substrates must be prepared using → Chapter „Pneumatic brush grinder set -VAS 6446-“. In addition, they must be sanded down to the bare metal using P40-grade sandpaper. If necessary, clean soiled surface again, and remove any residue from cleaning using brush grinder set.
 

2-pack diamond aluminium filler

Application
Manner of application:
–  With filling knife
 

2-pack diamond aluminium filler

Mixing ratio:
–  The two components are mixed in a ratio of 1 part liquid hardener to between 2.5 and 3 parts powder (or 10 grams of liquid hardener and 25 grams of powder) to a consistency which may be worked with a filling knife.
  Note
Avoid adding excessive amounts of liquid hardener, as this will impair the final hardness and adhesion characteristics of the filler.
Pot life:
–  Pot life at +20°C ambient temperature approximately 4 to 6 minutes
Reaction temperature:
–  At least +5°C
Drying
 

2-pack diamond aluminium filler

Air drying:
 

2-pack diamond aluminium filler

–  Flash-off time approx. 10 minutes
–  Curing by means of short-wave infrared dryer
  Initial curing: 10 minutes at 50 °C
  Full curing, stage 1, 10 minutes at 75 °C
  Full curing, stage 2, 10 minutes at 85 °C
 

2-pack diamond aluminium filler

Sanding
–  The obviously excess material can be removed before final thermal curing using the body plane. Then sand to contour using P80-grade dry sandpaper.
Processing:
No limitation
  Note
  •   Use only in well-ventilated rooms.
  •   It is recommended to wear safety gloves and a dust mask.
  •   It is recommended to use a dust collector.
Data
 

2-pack diamond aluminium filler

Viscosity as supplied Powder + liquid hardener
Flash point: Hardener, 33 °C
Powder, not applicable
 
Storage
The guaranteed shelf life is 12 months from date of production. May be used until the date stated on the label at latest if stored in sealed original containers at +20 °C.
   
Storage conditions
–  Store cool and dry.
–  Storage temperature +20 °C
 

2-pack diamond aluminium filler

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...

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