Rocker Outer Panel Sectioning - Front (Collision Repair)

Make

Vauxhall

Model

Astra J

Section

Collision Repair › Repair Instructions › Rocker Outer Panel Sectioning - Front

Body RepairRocker Outer Panel Sectioning - Front

Rocker Outer Panel Sectioning (Front) Note:  According to different corrosion warranties, only the regional mandatory joining methods are allowed. Removal Procedure Warning:  Refer to Approved Equipment for Collision Repair Warning . Warning:  Refer to Collision Sectioning Warning . Warning:  Refer to Glass and Sheet Metal Handling Warning . 1. Disable the SIR System. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove all related panels and components. 4. Visually inspect the damage. Repair as much of the damage as possible. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.            6. Create cut lines on the rocker outer panel - front (1).            Note:  Do not damage any inner panels or reinforcements. 7. Cut the rocker outer panel - front (1) where sectioning is to be performed.            8. Locate and mark all the necessary factory welds of the rocker outer panel - front (1). 9. Drill all factory welds.            10. Remove the damaged rocker outer panel - front (1). Installation Procedure            1. Cut the rocker outer panel - front (1) in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint. 2. Prepare all mating surfaces as necessary. 3. Align the rocker outer panel - front. 4. Clean and prepare the attaching surfaces for spot welding.            Note:  In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive. 5. Apply structural adhesive (1) to the attaching surfaces.            6. Position the rocker outer panel - front (1) on the vehicle. 7. Verify the fit of the rocker outer panel - front. 8. Clamp the rocker outer panel - front into position.            9. Spot weld the rocker outer panel - front (1) accordingly.   •  Upper flange (2) - 9 spot welds   •  Lower flange (3) - 9 spot welds            10. Braze the rocker outer panel - front (1) accordingly.   •  Rocker outer panel (2) - 350 mm   •  Rocker outer panel (3) - 350 mm 11. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze. 12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 13. Paint the repaired area. 14. Install all related panels and components. 15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 16. Enable the SIR system. Refer to SIR Disabling and Enabling .

04 Body & interior