Replacement (page 3 of 4)

6. Set the new front bulkhead.

• Grind both sides of the welding section of the bulkhead with a sander to remove the undercoat and expose the steel plate.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

• Clamp both the right and left sides with the vice-grips as shown.

NOTE: Apply the spot sealer to the welding surface when spot welding.

• Check the front bulkhead position using the body dimensional drawings.

7. Tack weld the new front bulkhead.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

• Spot weld the clamped sections.

NOTE: Make sure that the right and left side bulkheads are in line with each other.

8. Measure the front compartment diagonally with a tracking gauge or convex tool as shown to check it for twisting or bending.

9. Temporarily assemble the bonnet, headlight and front wing, then check the clearances and level differences.
10. Perform the main welding.

• Spot weld the bulkhead as shown.
• Make 20% to 30% more spot welds than there were holes drilled.

WARNING: To prevent eye injury and burns when welding wear an approved welding helmet, gloves and safety shoes.