Hyundai i30 / Elantra Neos. Body repair manual — part 2

GENERAL INFORMATION

GI-7

FOR BEST RESULTS

REMOVAL

Measuring dimensions before beginning
Measure the dimensions of the damaged area according to the body dimension drawings before removing and repairing.
Adjust dimensions with body frame adjuster if deformed.

Selecting cutting area
Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding.
Select an area that would allow the new part to overlap repair area by 30~50 mm (1.2~2.0 in) .

Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.

BFDGI6005

GI-8

GENERAL INFORMATION

Removing
Use caution when removing body molding and trim from
the area to be worked.
Apply masking tape where needed to prevent damage to
the part being removed or to the vehicle body.
Before starting repairs, check if pipes, hoses or electrical
components are present near damaged area.

BVQGI6006

Wire harness

Repair work area

Cutting area

GENERAL INFORMATION

GI-9

Machining holes for plug welding
Drill a hole of approximately 5~6 mm (0.2~0.24 in) in
diameter in those areas which are not suitable for spot
welding.

BVQGI6008

PREPARATION OF INSTALLATION

Applying spot sealer
Remove paint from the surface of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding method
If the thickness of the area to be welded with the panels overlapped is greater than 3 mm (0.1 in), do plug welding using a
carbon arc welding machine.

Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.

Adjusting a new part
The new part should be cut larger than the repair area,
overlapping the repair area by 30~50 mm (1.2~2.0 in).

BFDGI6007

Thicker than
3mm (0.1 in)

BVQGI6009

(1.2~2.0 in)

30~50 mm

(1.2~2.0 in)

30~50 mm

Overlap

Overlap

body side to modify

new part to modify

GI-10

GENERAL INFORMATION

INSTALLATION

Measuring dimensions before welding
When installing a new part, assemble it according to the body dimensions given in Section BD, and start welding after
checking the gaps with nearby parts.

Caution when welding
The number of welding points should be determined based on the criteria below:

Caution when spot welding
The tip of the spot welding machine should be maintained to a minimum of 3 mm (0.1 in) because it greatly affects welding
strength. When possible, spot welding should be done between the existing spot welded points.
Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the welding
strength.

(0.1 in)

3 mm

Center

diameter

Good

Existing welded spots

New welded spots

Using a hammer and a chisel

Using a test piece(test pin)

Nugget diameter
to be 4/5 of chip
diameter

No good

BVQGI6011

(0.1 in)

3 mm

BFDGI6010

Spot welding

Plug welding

Old part

Repair part

Pitch:
50 mm (2.0 in)

Increase the number of

spot welds by 30%.

Pitch: Same number of
welds as original part.

Pitch:
35 mm (1.4 in)

Repair part
more than
3 mm (0.1 in)