Welding precautions, aluminium panels welding (Panel repairs)

WELDING PRECAUTIONS, ALUMINIUM PANELS Welding

The body consists of a steel frame to which alloy outer General panels are attached. The front wings [fenders],door panels and body side outer panels are made from a special light magnesium-aluminium alloy.

These aluminium panels can be effectively repaired using the ’Argon Arc’ process of welding. This is a specialist operation which should only be carried out by specialist body shop, or an operator skilled in start. welding aluminium.

Under certain conditions it may not be practical to repair an exterior damaged panel. In such circumstances replacements for all exterior panels, except for the roof, can be fitted.

Impacts which do not deploy airbags

• CAUTION: Check for structural damage in
• the area of the impact, paying particular
• attention to bumper armature,
• longitudinals, crash cans and bracketry.

Panel beating Welding tears and patches

1. Aluminium alloy panels can be beaten out after accidental damage in the same way as sheet steel. However, under protracted hammering the material will harden and must then be annealed to prevent the possibility of cracking. Do this by heating the damaged area and allowing it to cool gradually.

• CAUTION: Due to the low melting point of
• the material, take care to apply heat only
• gradually.

CAUTION: Before applying heat to any panel ensure that the panel is clean and free from underseal and that the area to be worked on is well clear of any combustible materials. Ensure that all necessary precautions are taken against fire.

CAUTION: Disconnect the battery negative lead before welding operations start.

• WARNING: When welding near the fuel
• tank, drain the fuel system and remove the
• tank removed before welding operations

2. Clean off all grease and paint, and dry thoroughly. Clean the area to be repaired, including the edges, and extend this to at least 15mm (1 5/8 in) either side of the weld using a stiff wire scratch brush or steel wool for this purpose. In addition, clean the welding rod or strip using steel wool. It is essential to observe cleanliness in order to achieve a satisfactory repair.
3. Use only 5 per cent magnesium aluminium welding rod (5Mg/A), when carrying out repairs to the aluminium body panels.
1. When repairing a split or crack which extends to the edge of a panel, drill a small hole at the end furthest from the panel edge to prevent the damage from spreading. When welding, start the weld at the same point and work towards the panel edge.
2. When welding a long split or crack, or making a long welded joint, tack the edges to be welded at intervals of between 50 and 100mm (2 to 4 in) with spots. Do this by melting the metal at the starting point of the weld and fusing it into a small amount of the filler rod, repeating the process at the suggested intervals. After this, weld continuously along the joint increasing the speed of the weld as the material heats up.
3. When applying a patch to a hole, cut and trim the patch to the correct shape to fit the hole but leaving a gap of 0.8mm (1/32 in) between the patch and the panel. Proceed to weld as above.

CAUTION: Never apply an overlay patch.