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Table of Contents

Section 9: Body Repair

  • 8.

    A second and third application of compound may be required. Keep buffer moving over surface, this will help keep the surface cool. Clean compound residue off surface after each buffing operation. Do not continue to buff compound until dry.

  • 9.

    Buff the surface of the body when dry. When all scuff marks have been buffed out the surface may still appear a little dull, if so, proceed to #10.

  • 10.

    Install polishing pad #W-9006 on buffer (tan pad).

  • 11.

    Spread #8232 polish on surface as in step #3.

  • 12.

    Polish to a high luster or as required to match surrounding material.

  • 13.

    Wipe clean with soft clean cloth; any dirt on cloth will mar surface.

Deep Gouge

Required Tools and Materials (See note on page 37)

  • 1,000 rpm buffing tool, DeWalt #849

  • Evercoat Body Filler Easy Sand

  • Sanding Pad

  • DuPont Full-Thane Primer 421-15

  • DuPont 3939 Cleaner

  • DuPont Sealer 42470

  • DuPont Chroma Base/ Clear Coat Paint System

  • HVLP Paint Sprayer

Steps to Repair

  • 1.

    Sand damaged area with 500-grit paper to remove raised edges and to create abraded surface for proper adhesion.

  • 2.

    Fill damaged area with Evercoat body filler (2-part system) and allow to completely dry.

  • 3.

    Sand down high spots with 500-grit paper. If recesses are still visible due to filler shrinkage, apply second skim coat and again allow to dry completely, then sand surface flush with surrounding area.

  • 4.

    Apply DuPont Full-Thane Primer 421-15 over body filler.

  • 5.

    Once primer is completely dry, clean surface with DuPont 3939 Cleaner and again allow surface to dry completely.

  • 6.

    Apply 42470 Sealer over body filler.

  • 7.

    Apply color-matched paint system with HVLP paint sprayer according to supplier’s recommendations.


4400EX Heavy Duty Off Road Utility Vehicle 720-051M


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