Kia Carnival / Sedona (2006 year). Instruction — part 13

BP-6

BODY PANEL REPAIR PROCEDURE

CARBON ARC WELDING

In areas where spot welding is not suitable, do plug welding
using a carbon are welding machine.

1.

Clamp the parts to be welded together tightly. Do not
exceed 1 mm of space between parts. A tolerance
greater than 1 mm will reduce the strength of the
welded area.

2.

Weld in the middle of the flange joint.
a)

Drill a hole 5~6 mm on one side of the flange only,
and weld within the hole.

b)

Do not weld on the edge of the flange joint.

BVQBP6008

1mm

Maximum

tolerance

BVQBP6006

Good

BVQBP6009

No good

BODY PANEL REPAIR PROCEDURE

BP-7

REPLACING BODY PANEL

REMOVAL

1.

Body measurement
a)

Before removing, measure the damaged area
according to the dimensions supplied in Body
Dimension, section 31. If deformation is present,
use a frame straightener to adjust.

b)

When removing a panel, apply clamps to prevent
damage of each part, and support the lower end
of the frame to prevent deformation during the
procedure.

2.

Cut and welding point selection
Cutting, if necessary, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.

3.

Cutting rough area for replacement part
Cutting should be done according to the following steps
to make removal easy:
a)

Use care when cutting an area close to a pipe or
wiring harness.

b)

Cut an area leaving 30~50 mm of tolerance.

4.

Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.

BVQBP6010

Tracking gauge

BVQBP6011

Reinforcement

Reinforcement

Cut area

BVQBP6012

BVQBP6013

BP-8

BODY PANEL REPAIR PROCEDURE

5.

Determine a cutting method
a)

Cutting a spot welded area
Make a hole in the middle of spot welded area
with a punch, remove welded area using a spot
cutter and remove using a chisel.

b)

Removing brazed area
Remove using a torch and wire brush, and chisel.

c)

Removing arc welded area
Remove plug welded area using a disk grinder
and chisel.

BVQBP6014

BVQBP6015

BVQBP6016

BODY PANEL REPAIR PROCEDURE

BP-9

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.

NOTE

Do not spot weld where thickness is greater than
3 mm.

BVQBP6020

BVQBP6021

PREPARATION FOR INSTALLATION

1.

Spot weld finish
Use a disk grinder or similar tool to finish spot weld
mark, Do not grind more than is necessary to smooth
surface.

2.

Panel preparation
Repair any bent or uneven areas with a hammer to
improve the installation process.

3.

Cutting a rough area for a new part
When rough cutting an area for a new part, leave a
tolerance of 30~50 mm.

BVQBP6017

BVQBP6018

BVQBP6019