Hyundai i30 / Elantra Neos. Body repair manual — part 16
BODY PANEL REPAIR PROCEDURE
BP-3
NOTES WHEN WELDING BODY
REMOVING SPOT WELDED AREA
Most body parts are spot welded. In order to remove the damaged area, it is best to remove the spot welded area from the
body frame using a spot cutter or candle type edge drill bit.
Do not use a drill bit with a tapered edge. Center punch middle of spot weld to insure the entire spot weld will be removed.
BVQBP6002
1. Spot cutter
1. Drill(candle type edge)
1. Drill(taper edge)
2.
2.
2.
3.
3.
3.
Correct
Correct
Not correct
BP-4
BODY PANEL REPAIR PROCEDURE
BVQBP6003
Center punch the middle(nugget) of the spot weld.
Otherwise,
Spot welded area can be removed from the body frame.
Spot welded area cannot be removed from the body
frame.
This part will not be cut.
This part will be cut.
BODY PANEL REPAIR PROCEDURE
BP-5
SPOT WELDING
1.
Commercial spot welding machines do not perform as
well as the machines used in the manufacturing
process. When spot welding, increase the number of
spot welds by 30% (1.3 times the original number of
welds).
2.
When spot welding, weld in the middle of the joint.
•
Spot welding on the edge of the joint will reduce welding
strength.
BVQBP6005
BVQBP6006
Good
BVQBP6007
No good
INSTALLING A NEW BODY FRAME
The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of
plate, shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations.
Therefore, a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the
body.
DETERMINING A WELDING METHOD
It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body
be used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body components
other than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.
BVQBP6004
Welding
Symbol
Details
Spot welding
Oxygen-acetylene welding
Carbon arc welding
(Plug welding)
Not used
Use when spot welding cannot be done or spot welding is not necessary.
The most reliable welding method
(provides high efficiency and quality of assembled part.)
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
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