Repair of the damaged area

REPAIR OF THE DAMAGED AREA

Mild Steel Repair

1. Apply load to the damaged section and pull it out until the section is almost restored to the original shape.
2. Check that the parts of the body they cover have been more or less restored to their original shapes.

NOTE: Check the original position using the body dimensional drawings and the positioning jigs.

3. Remove the parts that require replacement.
4. Decide whether to cut the weld joint parts and replace partially, or whether to replace all the parts.
5. Cut off and separate the damaged parts.

NOTE: When cutting the parts off, take special care that you do not damage adjacent parts on the car.

Ensure that the following conditions can be met for the setting of replacement parts/joint sections:

• you can perform straightening work after welding.
• the locations are not susceptible to distortion caused by other parts.
• there are few removable parts and that the location allows safe welding.
• that the joints are short and that paint repair can be performed easily.
• the locations are such that the joints can be finished in a way that does not affect the outward appearance.
• the locations do not hinder the removing and attaching of parts.

NOTE: Bear in mind all of these conditions, and after determining the joint locations, cut the joints for an overlap of 20-30 mm.

6. Mould the related parts.
7. Set and tack weld the replacement parts.

NOTE: Temporarily mount the related parts and check the clearance and level differences.

8. Weld the replacement parts.

CAUTION: Protect body parts with the heat-resistant protective cover to prevent damage, when welding.

NOTE: Use of the positioning jig is recommended.

9. Apply anti-rust agent.

NOTE: The paint film, which is designed to prevent corrosion caused by moisture, is destroyed around the edges of the locations which have been repaired by welding. Therefore, in such places and especially in those areas which are not visible, apply another coat of the paint, referring to the rust-preventive treatments. This operation is designed to maintain durability and quality.