Vauxhall Workshop Service and Repair Manuals

1.

Before the start of work, a test weld/brazing is to be carried out on the area to be repaired (similar to a sample paint spray test ). This is done by subjecting a sample of the relevant panel joint to a test weld/brazing and seam check.

The sample panel must come from the vehicle to be repaired or be a new part.

2.

Structural seams (e.g. butt seam upon part replacement in the area of the front frame) are to be sealed with body sealant after priming. Before installing closure plates, make sure that corrosion protection is applied to areas such as the rear plate and weld seams in cavities. Inaccessible cavities are to be sealed as well.

Cavity sealling after painting is mandatory.

3.

The configuration of the welded and brazed joints for metal service parts sometimes differs from the seam configuration or joint specification used in production due to the different joining methods and joining order.

For example, slots must be made in certain service parts or body sections in order to create the joint.

For these such cases, the Service Literature explicitly specifies the configuration of the joint.

4.

For certain joining methods or seam geometries, it may be necessary to attach a reinforcing plate at the location of the joint. This plate serves to ensure a high-quality connection that has the same structural properties as a new part.

The reinforcing sheet metal is to be taken from the new part remnant or from the component of the sheet metal to be repaired. The Service Instructions provide information on the configuration and connection to be used for the reinforcing sheet metal.

In order to prevent structural breaches, the corners and edges of the reinforcing pate are to be deburred and bevelled.

5.

For structural seams (e.g. butt seams upon part replacement at the front frame), the deck/root seam must not be ground or smoothed. Reason: structural breach of the component upon grinding, notching or heat, uncontrolled reduction in metal thickness.

6.

Specific welding/brazing parameters are to be set for the individual seam areas based on equipment version.

This information is to be taken from the equipment manufacturer's documentation.

7.

Should a resistance spot welding spot require special settings, such is indicated by entering SPP in field 5!

Settings can be found in the parameter lists of the recommended equipment manufacturers.

Recommended manufacturers can be found in the newsletter.

8.

No spot weld primer is to be used at joints when using gas-shielded welding methods, such as MAG welding and MIG brazing. Reason: reduction of seam quality through gas emission, causing pore formation, which reduces the strength of the seam.

9.

Rivets are only to be used on metal body parts in combination with the adhesive sealing system.

Only waterproof, stainless steel rivets are allowed to be used. Use of aluminium rivets instead of steel is not permitted due to corrosion and insufficient strength.

For further information, see the Service Instructions.

1.

Resistance spot welding

A constant, high welding current and contact pressure of the welding pliers is required to attach high-strength, coated sheet metal. Satisfactory spot quality cannot be expected with conventional spot welding machines and welding pliers due to the differing power and compress air supplies available at various dealers.

The latest generation of spot welding machines (e.g. mid-frequency spot welding machines) have great advantages in this respect. The spot welds produced by these spot welding machines are of the same quality as those specified by the manufacturer for bodywork production.

2.

MAG (Metal Active Gas) welding

The MAG welding method has many applications when it comes to joining sheet metal, especially for uncoated and low alloy sheet metal.

MAG welding properties include:

• Seam temperature of approx. 1500°C
• higher zinc burning
• The outgassing of the zinc coating can lead to instable arcs and pores in the weld seam
• Base material is superficially fused
• Structural change in the base material in the area of the weld seam

Due to the particularities of the MAG-welding process, the connection area can have more or less pronounced weaknesses. These depend primarily on the type of coating and its thickness, as well as on the physical properties of the base material. For this reason it is essential to apply the MAG-welding process only in the areas specified in the Service Instruction.

Note:   The exact mode of procedure and areas of application can be taken from the appropriate Operations on TIS.

3.

MIG (Metal Inert Gas) brazing

MAG brazing offers a number of advantages when joining high-strength, coated sheet metal.

• Minimal heating (seam temperature approx. 950 °C)
• Minimal zinc melting loss
• Seam is protected against corrosion
• Base material is not superficially fused
• No structural change in the base material
• Good gap bridging

Thus, MIG brazing is suitable for joining high-strength, alloyed steel without changing its physical material properties.

4.

Rivets

The riveting technique is suitable as an additional joining technique in bodywork repair as an alternative to resistance spot welding. Rivets are always used in combination with the adhesive sealing system.

Use only Opel-approved, waterproof steel rivets for repairing metal body parts.

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www.ihsinfo.de

7.1 -

Rivet lengths and areas of application