GM Service Manual Online
For 1990-2009 cars only

Full-Cut Method Description for Saturn ION 2007

Use only the full cut method, also know as in the field as Full Strip Method, when installing windows.

This method includes the following:

  1. Remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive bead from the pinch-weld flange.
  2. Apply pinch-weld primer to any exposed painted areas on the pinch-weld flange.

Important: 

   • If corrosion of the pinch-weld flange is present, or if sheet metal repairs or replacements are required, refinish the pinch-weld flange in order to present a clean, primer-only surface.
   • If paint repairs are required, mask the flange bonding area, prior to applying the color coat, in order to provide a clean, primer-only surface.
   • Appropriate materials for these primer applications are typically 2 component catalyzed products. Use materials such as BASF DE15®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 ,5130® , PPG DP90LF SPIES/ HECKER 3688/8590 - 3688/5150 - 4070/5090 STANDOX 11158/13320 -- 14653/14980 products are approved for this application. Follow the manufacturer's directions for the mix, the application, and the drying times.
   • After repairing the opening as indicated, shake the pinch-weld black #3 primer well. Using a new dauber, apply the primer to the primed surface of the flange in the bonding area. Allow the primer to dry for 10 minutes.