 WARNING!
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Risk of explosion caused by grinding dust or carbon fibres!
Enriched sanding/grinding dust can lead to dust explosions in the presence of ignition sources.
Sanding /grinding dust can be electrostatically charged when evacuated with extraction systems and poses an ignition hazard.
Always wear fine dust filter masks, safety glasses and protective gloves when handling carbon reinforced plastic materials.
| • | The extraction systems must be grounded to prevent a dust explosion.
| | • | Avoid stirring up dust, immediately extract all dust caused by sanding/grinding with approved vacuum cleaners when processing carbon reinforced plastic materials.
| | • | Use only tools that have connections for extractor units.
| | • | Wipe away remaining dust residues with a moist, lint-free rag.
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WARNING!
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Risk of explosion and injury when handling polyester and epoxy resins!
When processing polyester and epoxy resins with their hardeners, vapours result which are generally combustible.
The vapours from liquid polyester and epoxy resins with hardeners and their mixtures are a health hazard. Direct contact with skin or eyes result in irritation.
No smoking!
| • | No open flames!
| | • | Always use skin protection cream, protective gloves and safety glasses.
| | • | Provide for good ventilation at workplace.
| | • | Do not eat or drink at workplace.
| | • | Keep storage containers closed wherever possible or close immediately after use.
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WARNING!
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Risk of explosion caused by handling organic peroxide hardeners!
When processing organic peroxide hardeners, vapours are produced and can explode when ignited.
Keep storage containers wherever possible or close immediatley after use.
| • | No smoking!
| | • | No open flames!
| | • | Provide for good ventilation at workplace.
| | • | Always use skin protection cream, protective gloves and safety glasses.
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| |
WARNING!
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Sharp vehicle parts.
Caused by scraping or cutting.
Always wear protective gloves when working on or near sharp and burred vehicle parts.
| • | Repair panels must be deburred.
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WARNING!
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Inhaling, or skin and eye contact with carbon fibres.
This dust or fibres irritate the bronchial tubes and may cause damage to the lungs.
Fibres that get stuck in the lungs can cause damage to the lungs.
Wear respiratory protection, protective gloves and safety glasses.
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WARNING!
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Contact with polyester and epoxy resins.
The vapours from liquid polyester and epoxy resins with hardeners and their mixtures are a health hazard.
Direct contact with skin or eyes result in irritation.
Always use skin protection cream.
| • | Wear protective gloves and safety glasses.
| | • | Ensure that the area is well ventilated.
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| |
WARNING!
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Contact with organic peroxide hardeners.
Direct contact with skin or eyes result in irritation.
Always use skin protection cream.
| • | Wear protective gloves and safety glasses.
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Generic Repair - Wet lay up
| | | Care Point: | Please create cardboard templates in the following diameters:
• 80mm
• 100mm
• 120mm
|
| Care Point: | Maximum area of damage that is repairable is 30mm radius (60mm diameter) from the centre point of damage.
|
| Care Point: | If the damage area exceeds this specification, please contact your regional aftersales manager immediately.
|
| | | 1. | Remove all detachable components that are situated around the repair area.
| | |
|
| 2. | Determine centre of damage point and highlight by drawing a circle of 30mm radius in white chinograph from this point (A).
| | | 
|
| | | Care Point: | Zone B = A + 20mm on radius (50mm R)
Zone C = A + 30mm on radius (60mm R)
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| | | 3. | Once damage point has been determined, mark out 2 more zones (B, C).
| | | 4. | Apply masking tape around the outside of zone C.
| | | 
|
| | | Care Point: | Damage point must be deburred before it can be repaired.
|
| | | 5. | Cut out zone A with a suitable straight die or pencil grinder.
| | | 
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| | | Care Point: | Damage point must be properly abraded before it can be repaired.
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| | | 6. | Chamfer zone A to from 60mm to 100mm.
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| 7. | Prepare carbon fibre for generic repair using suitable tool.
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| | | Care Point: | Observe all specifications for type of repair being carried out and also the materials being used.
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| | | 8. | Move work to clean area and allow the work to acclimatise to the new room temperature before continuing.
| | | 
|
| | | Care Point: | Follow all manufacturers' specifications and data sheets when mixing resins.
|
| Care Point: | Resin specified for all generic repairs on McLaren Super Series are as follows:
• Huntsman Araldite LY5052 - Resin
• Huntsman Aradur LY5052 - Hardener
|
| | | 9. | | | | 
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| | | Care Point: | The vacuum bagging material must be 2 xs bigger than the amount of carbon cloth.
The gap between the edge of the carbon cloth and the bagging material must be a minimum of 10mm.
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| | | 10. | Cut a section of vacuum bagging material and place on work surface.
| | | 11. | Cut an adequate amount of carbon fibre cloth and place this on top of the bagging material.
| | | 12. | Pour resin mixture on to carbon sheet.
| | | | | Care Point: | The carbon cloth must be completely enveloped in bagging material.
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| | | 13. | Fold over remainder of bagging material so that the carbon cloth remains flat.
| | | | | Care Point: | Make sure there are no air bubbles present.
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| | | 14. | Use plastic spreader to fully wet out the cloth with resin.
| | | 
|
| 15. | Use templates previously made and mark out on to the top pf the bagging material (1, 2, and 3)
| | | | | Care Point: | The resin must partially cure (20 minutes at regular room temperature) so that it becomes tacky.
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| | | 16. | Cut out repair patches marked on to cloth from templates.
| | | 
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| | | Care Point: | Remove masking tape before applying repair patches to damaged area.
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| | | 17. | Position patch 1 (80 mm diameter) over the repair area and place in a 0/90 degree orientation.
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| 18. | Position patch 2 (100 mm diameter) over the repair area and place in a +/- 45 degree orientation to the first patch.
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|
| 19. | Position patch 3 (120 mm diameter) over the repair area in a 0/90 degree orientation to the second patch.
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| 
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| | | Care Point: | Observe the manufacturers information regarding cure times and temperatures for specified resin.
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| | | 21. | Give the repair sufficient time to cure whilst under vacuum.
| | | 22. | Remove vacuum bag from repair area.
| | | 23. | Perform any subsequent treatment/ beautification required to the repair area.
| | | 24. | Clean up repair area.
| | | 25. | Clean surrounding area.
| | | 26. | Install all detachable components previously removed.
| | | 
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Generic Repair - Tub/Floor
| | | Care Point: | Follow generic repair process steps for all preparation of resins and materials.
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| Care Point: | No repairs can be carried out if the damage is within 60mm of the seat mounting points.
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| Care Point: | The distance between repairs must be at least 60mm apart.
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| Care Point: | There is only a maximum of 3 repairs allowed in each of the specified areas.
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| Care Point: | If damage has gone through both sides of the floor section (sandwich), please contact your regional aftersales manager immediately.
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| Care Point: | All zone radiuses on the following images are 30mm.
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| Care Point: | Please refer to the following images to see what generic tub repair is permissible in each areas of the tub.
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| Care Point: | Zone (1) = Damage up to 60mm diameter can be repaired using generic repairs on the tub, and zone (1) specific repairs on the floor areas.
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| Care Point: | Zone (2) = Damage up to 60mm diameter can be repaired using zone (2) specific repairs on the floor areas.
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| Care Point: | If damage has occurred to the tub outside of these specified areas, please contact your regional aftersales manager immediately.
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| | | 1. | Tub underside view zone (1, 2).
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| 2. | Tub inner view zone (1, 2).
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| 3. | Tub rear view zone (1).
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Zone 1 - Specific floor repair
| | | Care Point: | Please create cardboard templates in the following diameters:
• 80mm
• 100mm
• 120mm
|
| Care Point: | Maximum area of damage that is repairable is 30mm radius (60mm diameter) from the centre point of damage.
|
| Care Point: | If the damage area exceeds this specification, please contact your regional aftersales manager immediately.
|
| | | 1. | Remove all detachable components that are situated around the repair area.
| | |
|
| 2. | Determine centre of damage point and highlight by drawing a circle of 30mm radius in white chinograph from this point (A).
| | |
|
| | | Care Point: | Zone B = A + 20mm on radius (50mm R)
Zone C = A + 30mm on radius (60mm R)
|
| | | 3. | Once damage point has been determined, mark out 3 more zones (B, C and D).
| | | 4. | Apply masking tape around the outside of zone D.
| | |
|
| | | Care Point: | Damage point must be deburred before it can be repaired.
|
| | | 5. | Cut out zone A with a suitable straight die or pencil grinder.
| | |
|
| | | Care Point: | Use 60mm core drill.
|
| | | 6. | Remove rocell foam floor core.
| | | 
|
| | | Care Point: | Damage point must be properly abraded before it can be repaired.
|
| | | 7. | Chamfer zone A to from 60mm to 100mm.
| | | 
|
| 8. | Prepare carbon fibre for generic repair using suitable tool.
| | |
|
| | | Care Point: | Observe all specifications for type of repair being carried out and also the materials being used.
|
| | | 9. | Move work to clean area and allow the work to acclimatise to the new room temperature before continuing.
| | |
|
| | | Care Point: | Follow all manufacturers' specifications and data sheets when mixing resins.
|
| Care Point: | Resin specified for all generic repairs on McLaren Super Series are as follows:
• Huntsman Araldite LY5052 - Resin
• Huntsman Aradur LY5052 - Hardener
|
| | | 10. | Use 60mm core drill to cut out replacement rocell foam core from section provided in carbon repair kit.
| | | | | Care Point: | Give sufficient time for resin to cure.
|
| | | 11. | Prepare resin and bond in new plug.
| | | 12. | Sand/file down foam plug to correct height if required.
| | | 13. | Clean area thoroughly.
| | | 
|
| | | Care Point: | Follow all manufacturers' specifications and data sheets when mixing resins.
|
| Care Point: | Resin specified for all generic repairs on McLaren Super Series are as follows:
• Huntsman Araldite LY5052 - Resin
• Huntsman Aradur LY5052 - Hardener
|
| | | 14. | | | |
|
| | | Care Point: | The vacuum bagging material must be 2 xs bigger than the amount of carbon cloth.
The gap between the edge of the carbon cloth and the bagging material must be a minimum of 10mm.
|
| | | 15. | Cut a section of vacuum bagging material and place on work surface.
| | | 16. | Cut an adequate amount of carbon fibre cloth and place this on top of the bagging material.
| | | 17. | Pour resin mixture on to carbon sheet.
| | | | | Care Point: | The carbon cloth must be completely enveloped in bagging material.
|
| | | 18. | Fold over remainder of bagging material so that the carbon cloth remains flat.
| | | | | Care Point: | Make sure there are no air bubbles present.
|
| | | 19. | Use plastic spreader to fully wet out the cloth with resin.
| | |
|
| 20. | Use templates previously made and mark out on to the top pf the bagging material (1, 2, and 3)
| | | | | Care Point: | The resin must partially cure (20 minutes at regular room temperature) so that it becomes tacky.
|
| | | 21. | Cut out repair patches marked on to cloth from templates.
| | |
|
| | | Care Point: | Remove masking tape before applying repair patches to damaged area.
|
| | | 22. | Position patch 1 (80mm diameter) over the repair area and place in a 0/90 degree orientation.
| | | 
|
| 23. | Position patch 2 (100mm diameter) over the repair area and place in a +/- 45 degree orientation to first patch.
| | | 
|
| 24. | Position patch 3 (120mm diameter) over the repair area in a 0/90 degree orientation to second patch.
| | | 
|
|
|
| | | Care Point: | Observe the manufacturers information regarding cure times and temperatures for specified resin.
|
| | | 26. | Give the repair sufficient time to cure whilst under vacuum.
| | | 27. | Remove vacuum bag from repair area.
| | | 28. | Perform any subsequent treatment/beautification required to the repair area.
| | | 29. | Clean up repair area.
| | | 30. | Clean surrounding area.
| | | 31. | Install all detachable components previously removed.
| | |
|
Zone 2 - Specific floor repair
| | | Care Point: | Please create cardboard templates in the following diameters:
• 80mm
• 100mm
• 120mm
|
| Care Point: | Maximum area of damage that is repairable is 30mm radius (60mm diameter) from the centre point of damage.
|
| Care Point: | If the damage area exceeds this specification, please contact your regional aftersales manager immediately.
|
| | | 1. | Remove all detachable components that are situated around the repair area.
| | |
|
| 2. | Determine centre of damage point and highlight by drawing a circle of 30mm radius in white chinograph from this point (A).
| | |
|
| | | Care Point: | Zone B = A + 20mm on radius (50mm R)
Zone C = A + 30mm on radius (60mm R)
|
| | | 3. | Once damage point has been determined, mark out 3 more zones (B, C and D).
| | | 4. | Apply masking tape around the outside of zone D.
| | |
|
| | | Care Point: | Damage point must be deburred before it can be repaired.
|
| | | 5. | Cut out zone A with a suitable straight die or pencil grinder.
| | |
|
| | | Care Point: | Use 60mm core drill.
|
| | | 6. | Remove rocell foam floor core.
| | |
|
| | | Care Point: | Damage point must be properly abraded before it can be repaired.
|
| | | 7. | Chamfer zone A to from 60mm to 100mm.
| | |
|
| 8. | Prepare carbon fibre for generic repair using suitable tool.
| | |
|
| | | Care Point: | Observe all specifications for type of repair being carried out and also the materials being used.
|
| | | 9. | Move work to clean area and allow the work to acclimatise to the new room temperature before continuing.
| | |
|
| | | Care Point: | Follow all manufacturers' specifications and data sheets when mixing resins.
|
| Care Point: | Resin specified for all generic repairs on McLaren Super Series are as follows:
• Huntsman Araldite LY5052 - Resin
• Huntsman Aradur LY5052 - Hardener
|
| | | 10. | Use 60mm core drill to cut out replacement rocell foam core from section provided in carbon repair kit.
| | | 11. | Dry fit plug and sand/file to the correct height for the repair.
| | | 12. | Clean area thoroughly.
| | | 13. | Prepare resin and section of cloth as you would for a generic wet lay up.
| | | 14. | Remove plug and wet lay up 2 plies of cloth, one at 0/90 degree orientation and the second at +/- 45 degree orientation around the foam plug.
| | | 15. | Fit carbon covered plug into repair zone A.
| | | 
|
| | | Care Point: | Follow all manufacturers' specifications and data sheets when mixing resins.
|
| Care Point: | Resin specified for all generic repairs on McLaren Super Series are as follows:
• Huntsman Araldite LY5052 - Resin
• Huntsman Aradur LY5052 - Hardener
|
| | | 16. | | | |
|
| | | Care Point: | The vacuum bagging material must be 2 xs bigger than the amount of carbon cloth.
The gap between the edge of the carbon cloth and the bagging material must be a minimum of 10mm.
|
| | | 17. | Cut a section of vacuum bagging material and place on work surface.
| | | 18. | Cut an adequate amount of carbon fibre cloth and place this on top of the bagging material.
| | | 19. | Pour resin mixture on to carbon sheet.
| | | | | Care Point: | The carbon cloth must be completely enveloped in bagging material.
|
| | | 20. | Fold over remainder of bagging material so that the carbon cloth remains flat.
| | | | | Care Point: | Make sure there are no air bubbles present.
|
| | | 21. | Use plastic spreader to fully wet out the cloth with resin.
| | |
|
| 22. | Use templates previously made and mark out on to the top pf the bagging material (1, 2, and 3)
| | | | | Care Point: | The resin must partially cure (20 minutes at regular room temperature) so that it becomes tacky.
|
| | | 23. | Cut out repair patches marked on to cloth from templates.
| | |
|
| | | Care Point: | Remove masking tape before applying repair patches to damaged area.
|
| | | 24. | Position patch 1 (80mm diameter) over the repair area and place in a 0/90 degree orientation.
| | |
|
| 25. | Position patch 2 (100mm diameter) over the repair area and place in a +/- 45 degree orientation to first patch.
| | |
|
| 26. | Position patch 3 (120mm diameter) over the repair area in a 0/90 degree orientation to second patch.
| | |
|
|
|
| | | Care Point: | Observe the manufacturers information regarding cure times and temperatures for specified resin.
|
| | | 28. | Give the repair sufficient time to cure whilst under vacuum.
| | | 29. | Remove vacuum bag from repair area.
| | | 30. | Perform any subsequent treatment/beautification required to the repair area.
| | | 31. | Clean up repair area.
| | | 32. | Clean surrounding area.
| | | 33. | Install all detachable components previously removed.
| | |
|