Carrying Out the Repairs

Carrying out the repairs

Butt joint







NOTE:
- The severance cut should always be kept as short as possible on sectional replacement. Only cut at the severance lines shown in the repair chapters.
- Do not make any cuts near reinforcements or pre-determined folding lines.

- Prepare parts remaining on the vehicle/new parts.
- Reshape the adjoining surface of any dented body parts that are to remain on the vehicle using a hammer and a counterhold (Make sure that the old part matches the shape of the new part). Grind off left over spot welds or seams with an angle grinder.
- Cut the new parts to shape.
- If necessary punch or drill holes for mig plug welding.

- NOTE: Do not use a welding torch to remove paint residue (the heat could cause the metal to deform).

Grind all joining flanges to bare metal on both sides. Do not use an angle grinder for this purpose (this could weaken the metal and damage the zinc layer). Suitable tools: rotating wire brush, belt sander or plastic disc.

- Apply welding primer liberally to all weld flanges.
- The primer must be well stirred before use.

NOTE: When using aerosols, take care not to contaminate adjacent parts with spray mist.

Fit the new part.
- It must be Make sured that the new part fits exactly to the specified dimensions. Suitable equipment:
- Alignment jig.
- Universal measuring system.
- Jig system.
- Ruler or tape measure.
- Compass.
- Frame dimensions can be found in the model-specific repair manuals.

- NOTE: Any attached body parts that require accurate alignment and fitting must be incorporated in this step; for instance bumpers, seals, headlamps, rear lamps and lock assembly components. If this is not done carefully it may result in water leaks, wind noises and substantial follow-on work.

Make sure that edges line up with adjacent parts and check that gaps are consistent (compare left and right-hand sides). Make sure that the shape of the vehicle is retained.

Secure the new part

- NOTE: The need for subsequent follow-on work can be significantly reduced if aligning and tack-welding are carried out with due care.

Depending on accessibility the following methods for securing are available:

- Grip pliers (set of).
- Screw clamp (set of).
- Self-tapping screws.
- Tack welds.
- Use a staking tool or a screwdriver to Make sure that the edges of sectional replacements of profiled parts line up. The edge is then tack welded to Make sure that it lines up.

Aligning and tack weld










- Longer joins are usually tack welded to prevent the panel from warping. It is important to carry out the tack welds in the correct sequence (see diagram).
- Weld in the new part following the instructions in the repair manual.

Correct tack welding sequence







Follow on repairs/corrosion protection
- This step basically covers the following work:
- Grinding welded seams.
- Priming any bare metal.
- Sealing welded seams.
- Applying underbody protection.
- Sticking damping matting in place.
- Filling cavities with cavity wax.

- NOTE: See corrosion protection section for cavity wax application areas.

Cavity wax (after painting).