Mercedes-Benz Sprinter â€“ production at the DÃ¼sseldorf factory: Precision to a fraction of a millimetre - quality workmanship at the main van factory - Daimler Global Media Site
"Paintwork: emu feathers and ultra-fine coats of paint
Ten pretreatment stations and an extremely complex painting process provide the body of every van from Düsseldorf with perfect protection against corrosion. The pretreatment process is preceded by a so-called bodywasher: at this station the entire body is cleaned on the outside by rotating spray wheels and on the inside by other spraying equipment.
The actual painting process comprises zinc phosphating, cathodic dip priming, filler coat and top coat. All the coats are ultra-fine, with a total thickness of 80 thousandths of a millimetre. On average, the paintwork on every Sprinter weighs in at 17.4 kg, and the painted surface area totals around 95 square metres.
Prior to top-coating, each body is cleaned with emu feathers on rotating rollers to remove the finest dust. Robots and employees share the task of sealing the body seams averaging a total length of 138 m with PVC. The water-based top coat is applied on four lines. Several hundred different colours are possible. The top coat is applied using electrostatic systems – the fine paint particles are attracted to the body by electrostatic means.
Cavity sealing involves the same high degree of precision as the painting process: a large number of nozzles specified for each individual model automatically spray a precisely defined quantity of the protective coating into every cavity on the body. Together with the galvanised body panels, the sum total of all corrosion prevention measures provides permanent protection in all areas at risk of corrosion – rust has no chance."
Even cut to bare steel and close to the ocean salt mist cathodic ELPO should have preformed better then what you show.