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Economy system

Commercial Vehicle and Large Surface System

Fast, efficient and cost-focused painting of large surfaces such as trucks, buses, panel vans and trailers, with Lightweight Filler and economical 2K products.

Application steps

5 steps

Suitable substrates

  • Steel panel
  • Aluminium
  • GRP / Fibreglass

Ideal for

  • Truck and tractor unit cabs
  • Bus and minibus side panels
  • Panel van, cargo body and trailer surfaces
  • Periodic paint maintenance of fleet vehicles
About the system

Paintwork on commercial vehicles covers far larger surfaces than on passenger cars and is carried out to tight delivery schedules. On truck cabs, bus side panels, panel van bodies and trailers, every kilogram of material and every hour of labour feeds directly into the cost. The Commercial Vehicle and Large Surface System focuses on preparing large areas quickly and efficiently with easy-sanding Lightweight Filler and 4+1 Acrylic Primer Filler, which offers high filling power.

The colour coat is applied with a basecoat or a single-stage topcoat that meets the fleet standard; when a basecoat is used, 2K Acrylic Clear Coat with 2K Acrylic Hardener protects the surface and adds gloss. The economical product line-up aims to deliver a reliable result while keeping the budget under control on high-volume work. Using the same product chain on different vehicles helps to ensure a consistent appearance across the fleet and predictable maintenance costs.

For mixing ratios, drying and flash-off times, refer to each product's own Technical Data Sheet.

Step-by-step application

  1. 01

    Cleaning and Preparation

    ZN-530Surface Cleaning Thinner

    First wash and dry the large surfaces, then wipe them section by section with the thinner to remove grease, road grime and silicone residues. Open up the damaged areas with P80, feather the paint edges with P120–P150 and key the surrounding areas to be primed with P240–P320.

  2. 02

    Filling

    ZN-140Lightweight Filler

    Mix the filler with 2–3% by weight of the hardener supplied in the pack and apply it in thin, even layers with a wide spreader; its light weight makes it easy to work on vertical surfaces too. Once dry, shape with P80–P120 and finish with P180–P240.

  3. 03

    Primer

    ZN-2104+1 Acrylic Primer Filler

    First cover any exposed bare aluminium with Joker Multi-Purpose Primer. Then mix the primer 4:1 by volume with 2K Acrylic Primer Hardener (ZN-410), reduce it to spraying viscosity with Acrylic Thinner (ZN-510) and apply 2–3 coats. Save time on large areas by sanding the dry primer with P400–P500 using a random orbital sander.

  4. 04

    Colour Coat

    Apply the basecoat or topcoat in the fleet colour to the primed areas and to sound existing paintwork prepared with P400–P500, keeping a wet edge and overlapping each pass. If a single-stage topcoat is used, the clear coat step may not be needed; if a basecoat is used, clear coat is essential.

  5. 05

    Clear Coat

    ZN-3102K Acrylic Clear Coat

    Mix the clear coat with 2K Acrylic Hardener (ZN-420) and Acrylic Thinner (ZN-510) and apply 2 coats, allowing 5–10 min flash-off between coats. For large parts that will not fit in the oven, allow the drying time at ambient temperature given in the Technical Data Sheet (TDS).

Benefits

What this system delivers

  • Speed on large surfaces

    Easy-sanding Lightweight Filler and high-build primer shorten preparation time on large areas, reducing the time the vehicle spends off the road.

  • Economical use of materials

    Low-density filler and economical 2K products help to keep the cost per square metre under control on high-volume work.

  • Consistency across the fleet

    Using the same product chain on every vehicle reduces differences in surface quality and gloss between vehicles painted at different times.

  • Suitable for different body materials

    With the correct surface preparation, the same system can be used on steel cabs, aluminium bodies and fibreglass parts.

Other systems

Planning a different job?

All systems
  • Standard

    Spot Repair System

    Confines stone chip, scratch and small dent repairs to the damaged area; blending aims for an invisible transition without repainting the whole panel.

    1. ZN-530
    2. ZN-130
    3. ZN-230
    4. ZN-320
    5. ZN-520
    View system
  • Premium

    Premium Panel Repair System (HS)

    A panel repair system built on 5+1 HS Acrylic Primer and 2K Acrylic HS Clear Coat, aiming for high film build in fewer coats, deep gloss and a durable finish.

    1. ZN-530
    2. ZN-110
    3. ZN-130
    4. ZN-220
    5. ZN-330
    View system
  • Standard

    Standard Panel Repair System (MS)

    The standard system for everyday panel repairs: easy to apply with 4+1 Acrylic Primer Filler and 2K Acrylic MS Clear Coat, balancing cost and quality.

    1. ZN-530
    2. ZN-110
    3. ZN-210
    4. ZN-320
    View system

Let's build the right system for your workshop together

Talk to our team about product selection, application and pricing. We will quickly prepare the right system and quote for your needs.

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