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Standard system

Structural Damage and Deep Dent Repair

A layered repair system for deep dents, holes, cracks and weld areas: fibre-reinforced fillers provide strength and a finishing filler a smooth surface.

Application steps

7 steps

Suitable substrates

  • Steel panel
  • GRP / Fibreglass

Ideal for

  • Deep dents and crush damage
  • Small rust holes and cracks
  • Weld seams and panel joints
  • Breaks and cracks in GRP and fibreglass parts
About the system

Deep dents, small rust holes, cracks and areas that have been welded are exposed to mechanical loads that a standard polyester filler cannot withstand on its own. In this system, the damage is first reinforced with Fibreglass Filler: the glass-fibre reinforcement bridges small holes and forms a strong base that resists impact and vibration. Micro Fibreglass Filler then provides the transition between the coarse fill and the finishing layer, making the surface easier to shape.

Soft Finishing Filler covers pinholes and sanding scratches, while 4+1 Acrylic Primer Filler and 2K Acrylic Clear Coat complete the repair with an economical and durable finish. Bear in mind that damage to the chassis, pillars and other load-bearing areas must first be put right by panel straightening and, where necessary, panel replacement and welding. The filler system is used once the metal repair is complete, to restore the part's shape and surface quality.

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

    Once metal straightening and any welding are complete, sand the area with P80 and clean it thoroughly with the thinner. Take care to leave no rust residue, loose paint or weld slag behind.

  2. 02

    Reinforced Filling

    ZN-120Fibreglass Filler

    Mix the filler with 2–3% by weight of the hardener supplied in the pack and press it firmly into place so that it bridges the hole or crack; on fibreglass parts, first open the crack into a V-groove. Once dry, rough-shape it with P60–P80 and leave this layer slightly below the final surface level.

  3. 03

    Intermediate Filling

    ZN-125Micro Fibreglass Filler

    Apply the finer-textured Micro Fibreglass Filler over the fibreglass layer to complete the shape, then shape it with P80–P120. Depending on the extent of the damage, 3-in-1 Filler can also be used at this stage.

    Alternative: ZN-150 3-in-1 Filler

  4. 04

    Finishing Filler

    ZN-130Soft Finishing Filler

    Cover pinholes and sanding scratches with a thin skim of filler. Level with P150–P180, finish with P240 and check that the surface is true using a guide coat.

  5. 05

    Primer

    ZN-2104+1 Acrylic Primer Filler

    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. To reduce the risk of sinkage over large filled areas, sand the primer with P400–P500 only once it has fully dried.

  6. 06

    Basecoat

    Apply the colour-matched basecoat according to its manufacturer's instructions; on large repair areas, blending the colour into the adjacent panel helps to hide any difference in shade. Allow it to flash off to a matt finish before applying the clear coat.

  7. 07

    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 jobs that call for a fuller appearance, 2K Acrylic MS Clear Coat mixed with 2K MS Hardener (ZN-430) can be used.

    Alternative: ZN-320 2K Acrylic MS Clear Coat

Benefits

What this system delivers

  • Mechanical strength

    The glass-fibre-reinforced first layer helps to reduce the risk of cracking and detachment in areas exposed to impact and vibration.

  • Layered, controlled filling

    Using coarse, intermediate and finishing fillers in sequence allows the shape to be built up step by step and in a controlled way, even on deep damage.

  • Less sanding labour

    The Micro Fibreglass and Soft Finishing Filler layers reduce the laborious sanding of the coarse fibreglass surface, shortening labour time.

  • One system for steel and GRP

    Because the same product chain can be used on steel panels and fibreglass parts, stock management and team training are simplified.

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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