Diagram of fiberglass roof access hole cover plate installation…

TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) I.S. 6661, P.3


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28. Apply 190 degree F direct heat for five minutes using a heat gun. Hold the heat gun 8-10 inches from the inside surface of roof and sail panels and apply heat through the 3.5" x 5" access hole.

COVERING THE ACCESS HOLE
29. Shape cover plate by hand, to conform to contour of inner roof (refer to Figure 12).
30. Secure upper rear attachment with standard part sheet metal screw (refer to Figure 13).
31. Align cover plate over access hole and drill. Secure attachment holes in sequence (refer to Figure 14). Install each screw right after drilling hole. Do not drill several holes at once, otherwise holes may not match perfectly.
32. Remove sheet metal screws (refer to Figure 15).
33. Score the periphery of the plate and wipe clean (refer to Figure 16).
34. Apply two-part epoxy around the perimeter of the cover plate (refer to Figure 17).
35. Secure the cover plate to the inner roof with 6 rivets (refer to Figure 18 ).

PRIME, PAINT AND HOLD UNIT
36. Sand and clean the roof for priming.
37. Mix and apply (2.0 mils) urethane primer surfacer per manufacturers label.
38. Mix and apply (2.0 mils) topcoat material per manufacturers label instructions.
39. Re-install the fiberglass roof and all trim panels.
NOTE: If the vehicle was not equipped with a head liner, install one for the customer.
40. Hold the vehicle for 24 hours to ensure sufficient curing time for the two-part epoxy material.

Owner caption November 2004 · Photo 769 of 5000