Kia Sportage (2005+). Instruction — part 12

21-8

Replacing body panels

4. Preparation for spot welding

Remove paint on spot welded area and on the area
overlapped by the new part using a belt sander or
similar tool.

5. Drilling a hole for plug welding

If the thickness of the part to be welded is less than 3
mm, drill a 5~6 mm diameter hole. If the thickness of
the part to be welded is greater than 3 mm, drill a hole
using a 7 mm diameter drill.

Notice

Do not spot weld where thickness is greater than

3 mm.

1SD1BM021

1SD1BM022

Replacing body panels

21-9

Assembly

1. Checking welding and fitting in advance

a) When assembling a new par t, measure the

dimensions of each part according to the body
dimensions given in Section 31, and set part to the
reference dimensions.

b) Prior to final welding, check the fit of all related parts.

2. Selecting number of welding points

Spot welding : Multiply the original number of

factory welds by 1.3 times

Plug welding : Same number as original number of

factory welds

Notice

Plug welding should be done using a carbon arc
welding machine.
Brazing should be done only on areas that were
originally brazed at the factory.

3. Caution when spot welding

a) Do a test welding on a piece of material of the

same type and thickness as the part to be welded
and proceed if test weld is good.

b) Before spot welding, check if welding debris, oil or

paint is present on the area where surfaces meet.
Clean or sand as necessary.

1SD1BM02004

1SD1BM023

A3EB3259

A3EB3260

Center
diameter

3 mm

Using a test piece

Using a hammer
and a chisel

Nugget
diameter:
4/5 of tip

3mm

Spot welding:initial number of welds

x1.3

Plug welding-used when
spot welding is not
feasible or material is
thicker than 3 mm

Welding points-same number as original number of factory welds.

Initial welding
pitch:50 mm

Welding after repair
pitch:35 mm

21-10

Replacing body panels

c) The tip of the spot welding machine should be

maintained to a minimum tolerance of 3 mm. Also
let area cool after 5 or 6 welds to minimize
problems caused by excessive heat.

4. Cutting and welding an assembled area

To align a roof panel and a center pillar together for
butt welding, temporarily fasten a steel flange to the
roof panel and then apply the new center pillar panel.
Remove the flange when final welding is done.

5. Finishing after welding

a) Grind any areas that were plug welded or butt

welded using a disk grinder. Grind carefully to avoid
removing too much material. This degrades the
strength of the weld.

b) Finish areas that have been brazed by applying

body filler then smooth the area with a flexible file
and sander.

6. Applying anti-rust agent and body sealer

After coating the surface with anti-rust agent, apply
body sealer where necessary.

Notice

Apply body sealer before assembly.

7. Anti-rust treatment

Apply anti-rust agent to inside of doors and sills by

spraying through access holes provided.

3mm(0.12in)

1SD1BM026

1SD1BM027

1SD1BM029

1SD1BM030

1SD1BM028

A3EB3261

3mm(0.2 in)

Replacing body panels

21-11

Fender apron panel assembly

Welding part

BMKM023

9 Points

13 Points

26 Points

25 Points

D

C

A

A

C

B

B

E

E

D