1. Overlapping tolerance

Tools required:

• Reciprocating or circular saw
• Hand saw
• Scribe
• Shears.

1. Overlapping tolerance

POSITIONING AND CHECKING

a. Provisional assembly of new components.

Tools required:

• Adjustable clamp
• Squaring tool (sliding caliper)
• Chassis dimensional control system (template).

CAUTION:

• Position the components as shown in the diagrams of "BODY SQUARING".
• Correctly position the edges of the parts to be welded.
• Position mobile body parts (doors, bonnet and boot lid) then check the gaps, parallelism and squaring.
• Secure the parts to be welded with clamps or a few spot welds.

WELDING AND FINISHING THE SHEET METAL PART

a. All weldings should be carried out following the instructions given in "WELDING INSTRUCTIONS".

Tools required:

• Spot welder
• MIG welder
• Oxy-acetylene torch

b. After welding, remove the clamps used for securing the edges and remove any dints produced by them.

c. Smooth all welds using a sander.

Tools required:

• Pneumatic sander
• Disk sander
• Prelu with milling cutter.

CAUTION:

• When using the sander, care should be taken to avoid excessively reducing the thickness of the metal sheet as this may adversely affect welding strength.
• Remove the metal dust from the sanded surfaces and surrounding areas.
• Metal dust may cause corrosion.