Steel Body Parts - Repair, Remove and Replace

Steel Body Parts - Repair, Remove and Replace

Removal

1. Expose the resistance spot weld. For those spot welds that are not obviously visible use a rotary wire brush fitted to an air drill or a hand held wire brush.

   Caution: Do not burn off underseal, use a 'hot knife' or a suitable solvent.

2. Cut out the spot welds using a Zipcutter or roto-Bor. At this point it may be necessary to cut out the bulk of a panel using a pneumatic saw.

   Note: On some panels, before removing the bulk of the panel, brazed areas and MIG welded seams should be removed.

3. Separate the spot welded joints and remove the panel remnants.

Preparing Old Surfaces

1. Remove the weld nuggets with a sander and 36 grit disc.
2. Clean all flanges to a bright smooth finish.
3. Straighten existing panel joint edges as required.

Preparing New Surfaces

1. Mark off the area of the new panel and cut to size leaving approximately two inches overlap on the existing panel
2. Offer up the new panel or section and align it with the associated parts.
3. Clamp the panel into position.
4. Where necessary, cut the new and original panels to form a but joint.
5. Remove all clamps and the new panel.
6. If required, apply the inner panel protection and or sound insulation.
7. Prepare the new panel joint edges for welding by cleaning to bright metal, both interior and exterior edges.
8. Apply weld through primer or inter-weld sealer to all surfaces to be resistance spot welded.
9. Where appropriate, apply metal-to-metal adhesive or sealer in accordance with the manufacturer's instructions.

Panel Alignment

1. Align the replacement panel with the associated panel and clamp it in position.
2. With certain panels it may be necessary to tack weld or use PK screws.

Welding

1. MIG tack the butt joints.
2. Re-check the alignment and the panel contours as necessary.
3. Select the correct arms for resistance spot welding and ensure that the tips are correctly trimmed.

   Note: It is recommended that the arms are not more than 12 in (300 mm) in length.

4. Test the equipment for satisfactory operation using test coupons.

   In the absence of test equipment a satisfactory weld can be verified by pulling the test coupons apart and viewing the welded condition.

5. Resistance spot weld where required. Note the presence of zinc coated panels and treat as previously described.
6. Dress back all MIG tack welds.
7. MIG seam weld the butt joints.
8. Dress all welds as required.
9. Final braze and lead load as necessary prior to paint preparation.