aluminium wheel repair

Alloy Wheels Cosmetic Repairs using the ColorSystem

Recommendations and Method

Last update: 25.08.2009 of 26

Contents

1. Foreword 2. Restrictions of alloy wheel damage 3. Examples of damages 4. Recommended repair areas for substrate and paintwork damages 5. Prohibited repairs 6. Typical damages, repair recommended 7. Summary 8. Exemplary repair sequence 9. Colour shades


1. Foreword

The repair of alloy wheels is described in PS 97040 for the Repaint Shop, Finish and the VPCs. The description of the repair in this process regulation refers to paint materials. Substrate repair is generally forbidden here. Hitherto, this ban has also been transferred to the repair of alloy wheels in the BMW trade organisation. However, on account of the use of new paint and metal filling materials as well as today’s state of technology of modern repair methods, this appraisal no longer appears to be up to date and was challenged as a general rule. Involving the BMW specialist departments, substrate repair in the area of 1 mm deep and five centimetres away from the rim edge was discussed, the risk evaluated and declared as technically feasible. This repair recommendation is meant to be a guideline for the user in order to be able to carry out the alloy wheel repair in an area that BMW has determined as low-risk. All information contained in this repair guideline has a recommendatory character. Any alloy wheel repair carried out by the user in excess of the degree described in this catalogue shall be for the user’s own risk. This is why he should, in all events, adhere to the presented recommendations.

2. Restrictions By the EUWA: (Verband der Europäischen Hersteller von Fahrzeugrädern – Association of European Manufacturers of vehicle wheels): It is absolutely prohibited to repair a damaged rim or inner rim by heating, welding or by addition or removal of material By the ETRTO: (Technische Organisation der Europäischen Reifen- und Felgenhersteller – Technical Organisation of European Tyre and Rim Manufacturers): Damaged or deformed wheels, as well as wheels with slightly ripped or deformed bolt holes must not be repaired or put into operation. By the ColorSystem: Processing must only be carried out by specialised staff using the tested and recommended ColorSystem painting materials.


3. Examples of alloy wheel damages

Repair prohibited!

Repair allowed!


4. Recommended repair areas for substrate and paintwork damages Substrate repair: Approximately 90% of the occurring alloy wheel damages are to be found on the rim edge. On account of the damage and the preservation of rim stability an area is defined at a distance of 5 cm (green area) from the rim edge towards the alloy wheel centre (figure 1). In which substrate and paintwork repairs are recommended allowing for the following criteria. As substrate damage one defines the breach of the raw material aluminium. • The substrate is not damaged deeper than 1 mm • This involves a cast alloy wheel with the labelling (AlSi7, AlSi11, AISi12) • No fine machined alloy wheels • The repair is economical (cost/benefit consideration depending on the extent of the

damage, take working time and costs into account) • In the case of putty work it is only approved to use the Dual component aluminium putty

kit, with the BMW part number 83 19 2 154 174!

Paintwork: Generally it is allowed to paint alloy wheels with base coat and clear coat under consideration of the following points (repainting), it can be repaired without restriction on the entire front side of the rim (figure 2) • This involves a cast alloy wheel with the identification mark (AlSi7, AlSi11, AISi12) • In the case of fine machined alloy wheels only the clear varnish on the entire front side of

the wheel can be repaired • The repair is economical (cost/benefit consideration depending on the extent of the

damage, take working time and costs into account)

General information: • Subsequent turning on the lathe of fine machined alloy wheels is prohibited. • It is prohibited to paint the contact area between alloy wheel and tire (danger

off sliding). Use for masking the Soft-Edge Masking Foam Tape, part number 51 91 0 402 929.

• Paint work on the backside if the rim edge is not permitted • Alloy wheel treatment with sandblasting machines and their sandblast

materials is not permitted • On no account must the seat of the screw + borehole be painted! • The area of contact of the alloy wheel as well as the inner surface and the rim

well must not be painted!

Alloy wheel identification marking AlSi7 and AlSi11 (rear side)


Fig. 1 Fig. 2

Approved area of repair, green (substrate) Approved area of repair, green (paint)

5. Prohibited repairs

The following damages or types of alloy wheels must not be repaired: - All types of deformations - All types of cracks - All damage that occurs in the substrate and in the red area - All damage that shows up in the substrate at a depth of more than 1 mm (green and red area)

- Repairs are prohibited in the interior of the alloy wheel as well as on the rim well - Paint work on the backside if the rim edge - Alloy wheel treatment with sandblasting machines and their sandblast materials is not permitted

- Substrate repair on fine machined alloy wheels - Substrate repair on light metal forged alloy wheels

5 cm


In this case the customer should be advised here to replace the alloy wheel. In this respect a few interpretations follow in order to make the aforementioned points clear.

Damaged rim edge, substrate injury ≥1 mm, distance from the rim edge ≤ 5 cm Repair prohibited!


Damaged rim edge and rim surface area, ≤ 1 mm substrate injury at a distance of ≤ 5 cm to the rim edge. However at a distance of ≥ 5 cm to the rim edge substrate damage in the surface area/edge. Repair prohibited!

Fine machined alloy wheel. Substrate damage. Repair prohibited!


Damaged borehole side bolster, substrate injury ≤ 1 mm. However at a distance of ≥ 5 cm to the rim edge (red area). Repair prohibited!

Damaged rim surface area, substrate injury ≤ 1 mm. However at a distance of ≥ 5 cm to the rim edge (red area). Repair prohibited!


6. Typical damages, repair recommended

Damaged rim edge, substrate injury ≤1 mm, distance from the rim edge ≤ 5 cm. Repair possible!

Damaged rim edge, substrate injury ≤ 1 mm, distance from the rim edge ≤ 5 cm. Repair possible!


Damaged rim edge, substrate injury ≤ 1 mm, distance from the rim edge and paintwork damage ≤ 5 cm. Repair possible!




Damaged rim edge, Paintwork damage at a distance of ≥ 5 cm to the rim edge. Repair possible!


Damaged alloy wheel ridge, substrate injury ≤ 1 mm, distance from the rim edge ≤ 5 cm. Repair possible!

Distance to the rim edge ≥ 5 cm, can be repaired as no substrate damage. Repair possible!



Borehole side bolster with paintwork damage. Repair possible!


Wheel caps can be painted completely. Please observe the appropriate repair process for plastics!

7. Summary

• Generally it is allowed to paint the aluminium wheel with base coat and clear coat

(repainting) under consideration of the following points. • Levelling, chip-removing process (e.g. filing), heat input and addition of

material (with the exception of repair material from the Dual component aluminium putty kit, part number 83 19 2 154 174) are not admissible

• Bending back to original shape is not admissible • Paint work on the backside if the rim edge • Alloy wheel treatment with sandblasting machines and their sandblast materials is

not permitted • Radial and axial run-out before processing must not exceed the production

tolerance of 0.3 mm • Only cast light metal wheels must be repaired. These wheels have the

material identification marking AlSi7, AlSi11 or AlSi12 • Light metal forged alloy wheels must only be painted • Fine machined alloy wheels must only be painted • Only surface damage on the visible side of the wheel must be processed • Damage depth exceeding 1 mm is not allowed • Filling can be carried out up to 50mm from the rim edge • The repair must always be appraised following the use of balancing weights • Subsequent turning on the lathe of fine machined alloy wheels is prohibited • It is prohibited to paint the contact area between alloy wheel and tire

(danger off sliding). Use for masking the Soft-Edge Masking Foam Tape, part number 51 91 0 402 929.

• On no account must the seat of the screw + borehole be painted! • The area of contact of the alloy wheel as well as the inner surface and the

rim well must not be painted! • In case of drying with the infrared dryer (IRI) it is necessary to dismantle the

tire from the alloy wheel! • In the case of painting the complete front side it is necessary to dismantle

the tire from the alloy wheel!


8. Exemplary repair sequence

Note: On no account must areas marked in red be coated! For repair needed materials:

Dual component aluminium putty kit part number 83 19 2 154 174 25 mm Profi Tape part number 51 91 0 402 910 Rubber Squeegee part number 51 91 0 402 651 RPS Cup part number 51 91 0 428 934 Soft Pad superfine part number 51 91 0 402 860 P120 siaspeed 15 hole sanding disc part number 51 91 2 154 212 P180 siaspeed 15 hole sanding disc part number 51 91 2 154 214 P220 siaspeed 15 hole sanding disc part number 51 91 2 154 215 P400 siaspeed 15 hole sanding disc part number 51 91 2 154 219 Soft-Edge Masking Foam Tape part number 51 91 0 402 929 Masking paper, paint gun, HC Filler, HC Basecoat, HC Clearcoat

a. Clean the alloy wheel with a steam blaster


b. Dry the alloy wheel

c. Rough grind the alloy wheel (break sharp edges, P180 siaspeed sanding disc)

d. Blow off

e. Clean the damaged spot over a large area using silicone remover


f. Mix the Dual component aluminium putty kit, part number 83 19 2 154 174, follow instruction manual!

g. Depending on the room temperature, apply the aluminium putty to the damaged spot within 5-7 minutes

h. Use an infrared dryer to dry for 20 minutes


i. Level the dried aluminium putty by sanding (P120 siaspeed sanding disc)

j. Sand for applying filler (Soft Pad superfine)

k. Blow off

l. Use HC Cleaner to clean

m. Masking Mask backside of the rim edge


n. Apply filler

o. Dry filler

p. Sand filler (P400 siaspeed sanding disc, Soft Pad superfine)

q. Blow off


r. Use HC Cleaner to clean

s. Mask screw holes

t. Clean before applying base coat

u. Apply base coat, mask rim well + hub + area of contact prior to this!


v. Dry the base coat

w. Apply clear varnish

x. Dry the clear varnish

y. Result


9. Colour shades

The following colours are used for BMW, MINI and Rolls Royce alloy wheels:

BMW MINI Reflex silber met. (A44) Felgensilber Neu (144) Anthrazit met. / Schwarz 668 Bright Silver met. (A54) Kamacitgrau A91 Aspen White (899) Dekorsilber (A55) Jet Black (668) Ferricgrey met. (A80) Matt Anthracite met. (A66) Mattschwarz/ Schwarz 668 Schiefergrau (A97) Rolls Royce: Felgensilber Neu (144) You can find an overview of the alloy wheels used for BMW, MINI and Rolls Royce and a colour shade allocation in the Aftersales Assistant Portal on the ColorSystem homepage:

https://lpintrae.muc:5367/tetis/index.jsp?DOMAIN=B2E

� Parts and Accessories � ColorSystem � Informationen � Rim Colours Colour shades that are not listed should be identified by means of colour identification systems (e.g. CPS).

aluminium wheel repair

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