Panel replacement procedure (Panel repairs)

PANEL REPLACEMENT PROCEDURE

This procedure is designed to explain the basic panel removal and replacement method. The main criterion in removal and replacement of body panels is that the original standard is maintained as far as possible. While individual repairs will differ in detail, this procedure has been devised placing emphasis on ease of repair and the elimination of unnecessary work.

Body panels are being increasingly manufactured in high strength steels to meet design requirements for safety and weight saving. As panels in high strength steels cannot be visually identified, and as they are more sensitive to excess heat than panels manufactured from low carbon steel, it is advisable that the following procedure be observed at all times.

Remove panel

1. Expose resistance spot welds. For those spot welds which are not obviously visible, use a rotary impregnated wire brush fitted to an air drill, or alternatively a hand held wire brush.

NOTE: In wheel arch areas it may be necessary to soften underbody coating, using a hot air gun, prior to exposing spot welds.

2. Cut out welds using a cobalt drill.

3. Alternatively, use a clamp-type spot weld remover.