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We are writing this
letter to inform you that we have found incidents of composite bodies that
are not molded according to our current molding procedures. Please read
this letter carefully to make sure that if this affects you, the
appropriate action can be taken.
Background:
Two years ago
we upgraded our composite molding process. Prior to this, bodies were
laminated with a seam in the first layer of the fiberglass directly below
the parting lines left from the molds in the gel-coat. With these bodies
customers were instructed to remove material at the parting lines down
until the seam is no longer visible, and then fill the area back in with
fiberglass filler. If this procedure was not followed, there was a chance
that the seams could (over time) be seen thru the paint.
With the advent of the Mark II version kits we
changed our molding process to eliminate the seams in the first layer of
the fiberglass. The outward appearance of the new bodies, and the old
bodies are identical, but the new bodies are easier to prepare for paint.
Description of Variance:
As a result
of a recently received customer report (that an FFR composite body
contained “seams”) we conducted a review of our molded parts on our shop
floor as well as some at our supplier. We found that some of our recently
made stock bodies (both Mark II and Mark III) were made the old way.
Results of
Investigation:
After careful
investigation we have concluded that some of the bodies produced between
the April 24 and July 21, 2004 may have been manufactured using the old
process. We are sending this letter to customers that received kits
within this time period.
Corrective
Action:
While the
additional time to correctly prepare these bodies for paint compared to
the newer bodies is relatively minor, the consequences of failing to
correctly prepare the bodies can result in an imperfect paint job.
All of the bodies are indeed good and usable
product. Thousands of FFR kits have been built using both the older and
newer style laminates. Although most experienced body shops will already
know how to finish either body, bringing this to their attention will
ensure a correctly finished body. This information is mostly a concern to
customers painting the body themselves who do not have much body work
experience, or are having the paint done by someone else that also may not
have the experience to determine upon inspection the proper body work
required. We had changed the process in which we manufactured the bodies
specifically to make it easier for the do it yourself customers. Below
is a link to a procedure to follow for correct body preparation. As long
as the body is prepared correctly there is no reason to be concerned.
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