GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 2003 🢒 Unit Repair 🢒 Body and Accessories 🢒 Plastic Panel Information and Repair 🢒 Partial Panel Replacement

When you splice a replacement panel or a portion of a replacement panel to an existing panel, use the following procedure:


    Object Number: 95551 Size: SH
  1. Clean and inspect the damaged area. Refer to General Plastic Repair .

    2. Object Number: 95553 Size: SH
  2. Cut the damaged area and/or the replacement panel to the appropriate size so that the panel fills the opening.

    3. Object Number: 95556 Size: SH
  3. Scuff sand the damaged area and the replacement panel's mating surfaces.

    4. Object Number: 95567 Size: SH
  4. Fit the panel to the opening:
    5. • If the bonding strips are exposed, mechanically attach (1) and bond the strips together.
    • If the bonding strips are not exposed, cut or grind the edge of the panels in order to form a good butt joint (3). Then bevel the edges (2) to about 30 degrees in order to form a dished butt joint.

    Object Number: 366225 Size: SH
  5. Install a backing patch (3). Refer to Backing Patch Fabrication .

    6. Object Number: 95562 Size: SH
  6. Following the manufacturers instructions, mix and apply a light coat of the repair material to the outside of the damaged area.

    7. Object Number: 95561 Size: SH
  7. Lay a piece of reinforcement mat into the repair material.
    8. • The mat should extend 38-51 mm (1.5-2.0 in) beyond either side of the repair area.
    • All of the mat must be at a level below the final finished surface.
  8. Using an applicator, saturate and remove any trapped air from the repair area.

    9. Object Number: 95562 Size: SH
  9. Apply a second coat of the repair material in the same manner.

    10. Object Number: 95561 Size: SH
  10. Lay a second piece of mat into the repair area in the same manner.

    11. Object Number: 366225 Size: SH
  11. Apply the final layer or repair material in the same manner until the repair material (1) is at a level slightly higher than the surrounding area.

    12. Object Number: 193342 Size: SH
  12. Cure the material according to the manufacturers instructions.
  13. Apply and cure additional layers as needed.

    14. Object Number: 479231 Size: SH
  14. Rough out the surface using a #80 grit disc on a D A sander.

    15. Object Number: 95546 Size: SH
  15. Apply a polyester type material to provide a uniform surface for sanding, such as Sikkens® Polystop LP, or equivalent.
  16. Prime and refinish as necessary. Refer to the GM Approved Refinish Materials book GM P/N GM4901M-D which identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. This operation is to be performed prior to the application of sealers, waxes, deadeners, and antirust compounds. Follow the procedures recommended by the material manufacturer.