Title:

Service Bulletin – Proper Repair of Galvanized and E-Coat
Products

Number:

SB_624

Release Date:

12/11/2023

Revision Number:

1

Revision Date:

Not Applicable

Chassis Type:

All Custom Chassis Frame Rails with Galvanized or E-Coat
Corrosion Prevention

Component Description:

Frame Rail

Subject:
Proper Repair of Frame Rail Corrosion
Purpose/Background:
To consolidate the ASY Galvanized and E-Coat Frame Rail Repair Procedures into a combined communication to
provide proper instructions for repairing frame rails that have corroded due to wear/chipping over time, road
salt/brine, humidity, and improper cleaning after use.
Description/Procedure:
Galvanized Repair Procedure (PSD-0259)
Paints containing zinc dust with a concentration of 92% or above dried film (ZRC Galvilite recommended and
used in procedure).
Materials
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ZRC Galvilite
Sikkens M600 Solvent Degreaser

ZRC Galvilite Benefits
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•
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95% zinc in the dry film using only Type III “ultra-pure” ASTM-D-520 zinc (lead & cadmium free)
Recognized under the Component Program of UL as equivalent to hot dip galvanizing
Meets and exceeds Fed. Spec. DOD-P-21035A, MIL-P-26915A and ASTM Des. A-780
Passes 3,000 hours salt spray testing without failure (ASTM Des. B117)
Passes 9-year subtropical testing
Low VOC approved in all 50 states
ISO 9001 registration assures the highest quality consistently

Mixing
ZRC Galvilite must be thoroughly stirred until pure zinc content is completely dispersed. Initial mixing can be
done with a paint shaker.
Procedure
1. Remove loose galvanized coating.
a. If there is any pitting involved, needle scaling may be required.
b. Sand repair areas to a featheredge finish.
2. Remove grease, oil, and/or light oxides with Sikkens M600 solvent degreaser.
3. Apply ZRC Galvilite with a brush without thinning, to achieve a thickness of 2.0 mils. (One medium to
heavy coat will achieve the proper film build).
4. Replace the cover on the can to avoid the product from hardening.

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SERVICE BULLETIN #624.1
5. Allow coating to dry until dry to touch, in 20-30 minutes. Times may vary depending on thickness applied,
substrate temperature, and ambient temperature.
E-Coat Repair Procedure (PSD-0240)
Materials
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Wax and grease removing solvent
Bonderite Auto Prep Wipe
Sikkens LV260 Primer Epoxy
Sikkens LV260 Hardener
Sikkens LV262 Multi-Substrate Primer Epoxy
Sikkens LV262 Epoxy Hardener G2
Sikkens LV650 Topcoat Low Gloss Black (Pierce #99)

Procedure
1. If there is any pitting involved, needle scaling may be required.
2. Solvent wipe surface to be coated with a wax and degreasing solvent. Reference PSD-0084 (See
Appendix A).
3. Wipe bare metal areas to be coated with a Bonderite Auto Prep Wipe.
4. Sikkens LV260 Primer Epoxy or LV262 Multi-Substrate Primer Epoxy must be used to coat the bare metal
areas.
a. Sikkens LV260 Primer Epoxy uses 3 parts to 1-part LV262 Epoxy Hardener
b. Sikkens LV262 Multi-Substrate Primer Epoxy uses 3 parts LV262 Multi-Substrate Primer Epoxy
to 1-part LV262 Epoxy Hardener G2
5. Mix appropriate amount of epoxy primer for the size of the repair.
6. For all non-critical aesthetic areas, the epoxy primer may be applied with a paint brush.
7. To apply the epoxy primers with spray application equipment, reference PSD-0205 (See Appendix B) for
LV260 Primer Epoxy or PSD-0286 (See Appendix C) for LV262 Multi-Substrate Primer Epoxy.
8. Apply 1-2 coats of epoxy primer to achieve full coverage.
9. Allow epoxy primer to flash off until it is dry to the touch.
10. The area that the epoxy primer was applied to, will need to be coated with Sikkens LV650 Topcoat Low
Gloss Black (Pierce #99).
11. Mix appropriate amount of LV650 Topcoat Low Gloss Black for the size of the repair.
a. Sikkens LV650 Topcoat Low Gloss Black uses 6.5 parts LV650 Topcoat Low Gloss Black to 1part LV650 Hardener
12. To apply the LV650 Topcoat Low Gloss Black with spray application equipment, reference PSD-0217
(See Appendix D).
13. Allow LV650 Low Gloss Black to dry for 3 hours if ambient temperature is 70°F if assembly of the part is
required. Adding heat to the area will decrease the cure time.

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SERVICE BULLETIN #624.1
Appendix A - Solvent Wipe Procedure (PSD-0084)
Purpose
Solvent cleaning procedure for the removal of waxes, oils, silicones, and other organic contaminates prior to
seal priming and top coating.
Materials
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•
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•

Wax and grease removing solvent
Disposable rags
Rubber gloves
Breathing respirator
Safety glasses

Safety
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Follow all precautions described in the Material Safety Data Sheets for the solvent product.
Keep the solvent and rags away from heat, sparks and open flames.
Use with adequate ventilation. Do not breathe vapors.
Wear a respirator if using in an area that is not well ventilated.
Avoid contact with eyes, skin and clothing.
Wear rubber gloves during the entire solvent cleaning and rag disposal activities.
Wash skin thoroughly after handling.

Cleaning Procedures
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Wet a clean rag with a wax and grease removing solvent.
Make sure to pour solvent out of container or spray from an approved pressurized bottle.
With a clean towel, wipe off the surface before it has time to evaporate.
Replace towels regularly.
Repeat above steps as needed to remove all surface contaminates.

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SERVICE BULLETIN #624.1
Appendix B - LV260 Primer Epoxy (PSD-0205)
Description
LV260 Primer Epoxy is a two-component, high solids, low VOC, HAPs free epoxy primer. LV260 Primer
Epoxy is a fast-drying primer with excellent corrosion protection over multiple substrates. LV260 Primer Epoxy
is a versatile product that can be applied in a couple of methods:
•
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As a wet on wet, non-sanded primer-sealer
As a primer-surfacer that can be sanded for extra smoothness prior to top coating
High build primer
Primer sealer over sanded aluminum
High Build Primer
3 LV260 Primer Epoxy
1 LV260 Hardener

Medium Build Primer
Up to 1 part of Exempt Reducer
may be added as needed to thin

Use Sikkens Measure Stick #9

Spray gun set-up:
0.8 – 1.1 mm
36 – 44psi

Fluid delivery:
12 – 16 oz/min
Check gun manufacturer specification

Non-sanded primer sealer
Apply 1 medium flowing coat
Primer surfacer
Apply 2 medium flowing coats

Between coats
5 minutes at 70°F (21°C)

LV260 Hardener

Before topcoat
30 minutes at 70°F (21°C)

Dry to Touch
70°F (21°C)

Dry to Handle
30 min 1hr 40min

Use suitable respiratory protection
Akzo Nobel Car Refinishes recommends the use of a fresh air supply respirator
Refer to the product Safety Data Sheet (SDS) for complete safety information

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SERVICE BULLETIN #624.1
Appendix C - LV262 Multi-Substrate Primer Epoxy (PSD-0286)
Description
A two-component, high solids, heavy-metal free epoxy primer. Utilizing state-of-the-art corrosion inhibitive
pigments, it provides excellent corrosion resistance for various grades of aluminum and steel.
Mixing – High Build
3 Parts LV262 Multi-Substrate Primer Epoxy
1 Part LV262 Epoxy Hardener G2

Medium Build
10% LV260 Reducer
may be added to “A” volume

Use Sikkens Measure Stick #9

Spray gun set-up:
Fluid delivery:
1.0 – 1.4 mm
10 – 14 oz/min
Air Pressure - Check gun manufacturer specification
Application @ 60 – 95° F
Apply 1 – 2 single wet coats
Flash Between coats @ 70° F
5 – 10 minutes

Air Drying @ 70° F

Flash to Recoat
25 – 30 minutes

Dry to Touch
30 – 35 minutes

Dry to Handle
3 – 4 Hours

Use suitable respiratory protection
Akzo Nobel Car Refinishes recommends the use of a fresh air supply respirator
Refer to the product Safety Data Sheet (SDS) for complete safety information

Pot Life When Mixed
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Pot life will be influenced by mixing ratio and temperature
3-6 hours @ 70° F

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SERVICE BULLETIN #624.1
Appendix D - LV650 Topcoat Low Gloss Black (PSD-0217)
Description
LV650 Topcoat Low Gloss Black is a state of the art, high performance, two-component, high solids,
polyurethane, single stage coating. LV650 Topcoat Low Gloss Black has a gloss range of 30 – 40 at 60°
angle.
6.5
1

LV650 Topcoat Low Gloss Black
LV650 Hardener

For accurate mixing, use the centimeter ruler on the side of any Sikkens measuring
stick.
Spray gun set-up
Tip size
Fluid Rate
Air pressure

1.2 mm – 1.4 mm Pressure Feed
1.8 mm – 2.0 mm Siphon or Gravity
14 – 20oz/min
Check gun manufacturer specification

Apply two (2) single flowing coats or one cross coat
Object Temp
70°F
140°F

Drying
Dust Free
Tack Free
Dry to handle
Dust Free
Tack Free
Dry to handle

Unaccelerated
1 Hour
1.5 Hours
3 Hours
15 Minutes
30 Minutes
1 Hour

Use suitable respiratory protection
Akzo Nobel recommends the use of a fresh air supply respirator
Refer to the product Safety Data Sheet (SDS) for complete safety information

Additives
1 oz. of SuperTop per raw quart of A-component may be added to speed up cure time.

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SERVICE BULLETIN #624.1
Recoatability
Recoatable with itself after full drying cycle. Sanding becomes necessary after 24 hours.
Product Characteristics
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WPG
Volume Solids (RTS)
Pot Life (unaccelerated)
Gloss

9.08 lbs/gallon
47%
2 hrs @ 70°F
30 40 at 60°

Product Storage and Shelf Life
Store products unopened and used products with closed lids. Store products between 70°F-95°F.
Optimal storage temperature is 77°F. Avoid extreme temperature fluctuation when storing.
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LV650 Low Gloss Black
LV650 Hardener
SuperTop

2 years
1 year
6 months

If any additional support is needed, please open a technical support incident on Pierceparts.com.

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