landrover Workshop Repair Guides

Land Rover Workshop Service and Repair Manuals

Panel replacement procedure|Page 902 > < Panel replacement procedure
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PANEL REPAIRS

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PROCEDURES

5. Separate spot welded joints and remove panel 

remnants using hammer, bolster, chisel and 
pincers.

Prepare old surfaces

1. Clean all panel joint edges to a bright smooth 

finish, using a belt-type sander.

NOTE: Prior to sanding, remove remaining 
sealant using a hot air gun to minimise the risk 
of toxic fumes caused by generated heat.

Caution: Care must be taken to avoid 
excessive heat build up when using this 
equipment.

2. Straighten existing panel joint edges using a 

shaping block and hammer.

CAUTION: Never use the same tools for 
working with steel or aluminium. All tools 
used for working with steel must be kept 
separate from those used on aluminium.

Prepare new surfaces

1. Mark out bulk of new panel and trim to size, 

leaving approximately 50 mm (1.968 ins) 
overlap with existing panel. Offer up new panel/
section, align with associated panels (e.g. new 
body side panel aligned with door and trunklid). 
Clamp into position.

Panel replacement procedure|Page 902 > < Panel replacement procedure