Body and Frame: Description and Operation

Body Shell Welding - Introduction
The information which follows is concerned solely with the Monocoque assembly of the inner body shell on Range Rover models.

Body repairs often require the removal of mechanical and electrical units and associated wiring.

The inner body shell is of Monocoque construction and to gain access to the repair area, it may be necessary to remove exterior body panels, all exterior body panels are bolted to the inner body shell to facilitate easier panel removal and replacement or repair.

It is expected that a repairer will select the best and most economic repair method possible, making use of the facilities available, The instructions given are intended to assist a skilled body repairer by expanding approved procedures for panel replacement with the objective of restoring the car to a safe running condition and effecting a repair which is visually acceptable.

Welding
The following charts and illustrations show the locations and types of weld for securing the body side assembly, tailgate frame assembly and the front valance and wheel arch assembly. Before undertaking any spot weld joints to the inner body, it is advisable to make a test joint using offcuts of the damaged components, and to use this test piece to perform a weld integrity test.

Spot welding is satisfactory if the joints do not pull apart. If the weld pulls a hole or tears the metal the weld is satisfactory. It is defective if the weld joint pulls apart or if there are signs of burning, porosity or cracking evident.

Preparation
Thoroughly clean all areas to be welded, remove any sealants and corrosion protectives from around original panels. Align and clamp all new panels in position and check relationship to one another.