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I know Audi uses some sort of silicone-like compound to "glue" the body panels together in addition to bolting them. Seems like a good way to insure they will never rattle, but has potential for a huge mess during assembly.
I assume that 100% silicone would not have the longevity and something like NP-1 would be too permanent to ever get them apart again.
And there's the mastic products that are applied like tape, but I'm not sure if those would start to seep when they get hot.
Most manufacture use structural glue in automobile assembly - Check out the properties online or at your local parts place
I've used it on my old ladies car to get her to shut up about how long it was taking to get it fixed - The glued together parts have stayed attached much longer then we have.
You seem to have hit on two seperate subjects...permanent body panel adhesion and body panel rattle isolation. I am not sure that there are any "non-conventional" solutions since the state of the art in automobile manufacturing moves forward much faster than any of us "hobbyists" may realize. Your example of the Audi technique is a good one and would offer my perspective on the potential messiness...I don't think that any car manufacturer would use a technique that hasn't been thoroughly tested and perfected on the production line. That said, I am sure that any of us could make a mess of it since we do not have the controlled environment of an Audi plant. The tried and true method of using welting is still popular with many truck owners but I think that this was originally used by the OEM to control the poor fit of the panel rather than controlling squeaks and rattles.
I have used various RTV products when joining panels to control seepage between the panels. My interest was more in keeping the inner areas isolated from water than it was to eliminate rattles. The beauty of using a RTV or silicone gel-type product is that it conforms to the irregular surfaces better than a tape or even a foam product.
Way back in mid 70's when I put my 54 together I used the dumbo tape on fenders and front body parts. That's what my dad said to do at the time and it was his truck and parts. The truck still doesn't rattle or squeak. I will have more input when I tear down front later.
If you want to put panels together the body panel glue is great, I put the tubs in my truck with glue. As you put it together just keep the area cleaned up when it's curing to keep the edges smooth looking, no sanding like filler just scuff and paint, Garry
Haven't used it myself but Lords Adhesive Fuson has a super high lbs/sq.in. rating for bonding bare metal to metal. I have seen it used and it seems as strong as a weld. Don't know how it would be a decade after application though.
I agree with CharlieLed, these parts on our trucks just don't fit together anywhere near as well as modern car parts do. It would probably make one heck of a mess when you clamped them together with squeeze out in some areas and not enough glue in others. I like the welting for squeaks, and the RTV is a good idea for water blocking.
3M makes a panel bond product. It's a two part product that gets mixed together by using a fancy caulking gun when you are using it. It's basically like welding the panels together. Once it sets up you will never get it apart. It's pretty neat stuff.
Loctite makes an adhesive that is used on aircraft and semi trailers, takes about 72 hours to fully cure. When cured still stays somewhat pliable. I used it to add an inner wall to my truck bed, needed a little extra weight to help the ride and it cleaned up some issues with previous owners abusing the bed! I'll try to find if I have any more of it to give you the correct info in it but the stuff is amazing, it will not come apart! Much cheaper than the stuff you can obtain at the paint and body shop for body adhesives, I think it's a better product too. I think this is the stuff I used, it has some great bonding capablilities! Loctite makes other stuff for this purpose as well but this stuff seems to do the trick! Loctite 3370 One-Part Polyurethane Black - Henkel
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