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Galvanised Steel and Aluminium System

A premium repair system for galvanised steel and aluminium panels: dedicated fillers and Joker Multi-Purpose Primer reduce the risk of blistering and lifting.

Application steps

6 steps

Suitable substrates

  • Galvanised steel
  • Aluminium

Ideal for

  • Dents and scratches on galvanised steel panels
  • Aluminium bonnet, wing and door repairs
  • Galvanised cabs, cargo bodies and metal components
  • Premium vehicles with lightweight bodies
About the system

Today's vehicles increasingly use galvanised steel for corrosion resistance and aluminium panels for lower weight. These surfaces behave differently from conventional steel panels: the zinc layer can make it harder for standard fillers to adhere, while aluminium re-oxidises shortly after sanding. If the wrong products are chosen, problems such as blistering, intercoat delamination and, over time, corrosion beneath the paint can occur, meaning the repair has to be redone.

The Galvanised Steel and Aluminium System starts with Galva Filler or Aluminium Filler, both developed for these surfaces, and continues with the versatile Joker Multi-Purpose Primer. Keeping separate abrasives and tools for each type of metal helps to prevent steel dust from contaminating aluminium and causing contact (galvanic) corrosion. Finished with 2K Acrylic HS Clear Coat, the system is a premium solution for workshops aiming for long-lasting repairs on coated and light metals.

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

Step-by-step application

  1. 01

    Surface Cleaning

    ZN-530Surface Cleaning Thinner

    Remove all grease, silicone and dirt from the surface; on galvanised areas, always remove any white rust (zinc oxide) that has formed. Apply the thinner with one cloth and wipe it dry with a second, clean cloth before it evaporates.

  2. 02

    Sanding

    Key the area to be filled with P80–P120 and the surrounding area to be primed with P240–P320 or a grey scuff pad; for aluminium, use only abrasives, discs and tools reserved for that metal. Do not abrade the zinc layer more than necessary, and coat sanded aluminium without delay.

  3. 03

    Filling

    ZN-170Galva Filler

    Mix the filler with 2–3% by weight of the hardener supplied in the pack and apply it in thin layers, pressing it firmly into place; on parts exposed to heat and expansion, such as the bonnet, Aluminium Filler can be used instead. Once dry, shape with P80–P120 and finish with P180–P240.

    Alternative: ZN-160 Aluminium Filler

  4. 04

    Primer

    ZN-250Joker Multi-Purpose Primer

    Mix the primer with 2K Acrylic Primer Hardener (ZN-410) and Acrylic Thinner (ZN-510) and apply 2–3 coats, covering the filled area and all exposed metal. Once dry, sand with P400–P500 without cutting through to bare metal.

  5. 05

    Basecoat

    Apply the colour-matched basecoat according to its manufacturer's instructions so that it covers the entire primed surface evenly. Allow the basecoat to flash off to a fully matt finish before applying the clear coat.

  6. 06

    Clear Coat

    ZN-3302K Acrylic HS Clear Coat

    Mix the clear coat with 2K HS Hardener (ZN-440) and, if necessary, thin it with Acrylic Thinner (ZN-510). Apply 1.5 coats: first a light closed coat, then a full wet coat 3–5 min later. When baking, allow 30–40 min at 60 °C object temperature; when air drying, follow the times given in the Technical Data Sheet (TDS).

Benefits

What this system delivers

  • Reliable adhesion on difficult surfaces

    Fillers developed for galvanised steel and aluminium, together with Joker Multi-Purpose Primer, focus on reducing the risk of blistering and delamination.

  • Protection against contact corrosion

    Keeping separate abrasives and tools for each type of metal minimises the risk of corrosion caused by cross-contamination between different metals.

  • Uninterrupted protection

    Areas where the zinc layer has been damaged are quickly covered with a suitable filler and primer, protecting them against rust forming beneath the paint.

  • Premium finish

    2K Acrylic HS Clear Coat delivers deep gloss and a durable finish on light-metal panels too.

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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