Hyundai Atos: Body Repair Manual — part 21
89
BODY PANEL REPAIR PROCEDURE - Front side outer panel
5.
Drill out all welds attaching the front side outer panel to dash and
cowl top outer, cowl inner lower panels.
6.
Remove spotwelds and lap welds attaching cowl crossmember
bar mounting upper bracket to remove front pillar.
7.
Before cutting front side outer panel, be sure to support roof
panel.
8.
Cut the front side outer panel through each cutline, taking care
not to damage the other panel as illustrated.
9.
Before cutting the side sill outer panel, make a rough cut the side
sill outer panel only.
NOTE
When cutting the front side sill outer panel, be careful not
to cut side sill outer reinforcement.
PRO-0540
PRO-0550
PRO-0560
PRO-0530
Front side outer
panel
Front inner upper
pillar
90
BODY PANEL REPAIR PROCEDURE - Front side outer panel
10. Cut the side sill outer reinforcement as shown in the illustration.
11. Cut the side sill outer reinforcement vertical cutline and remove
the front side outer panel.
12. Straighten all flanges as necessary, prepare all surfaces to be
welded.
INSTALLATION
1.
Transcribe the cutline to the new front inner upper pillar , cut to
length and chamfer butt end to improve weld surface.
2.
Transcribe the cutline to the new side sill outer reinforcement
and new front side outer panel, adding 30mm overlap to end and
cut to length.
3.
Drill 8mm holes along outer panel flanges in production location
for attachment to other panels.
PRO-0580
PRO-0590
PRO-0570
PRO-0600
30mm
91
BODY PANEL REPAIR PROCEDURE - Front side outer panel
4.
Transcribe the cutline to the new side sill outer reinforcement,
adding 30mm overlap to end and cut to length.
5.
Drill 8mm holes in the side sill outer reinforcement for MIG plug
welding.
6.
Fit and clamp the new side sill outer reinforcement in place for
welding.
7.
MIG plug weld all holes and MIG butt weld the seams.
8.
Temporarily install front inner upper pillar and front side outer
panel in place.
9.
Measure and each measurement point (Refer to the BODY
DIMENSIONS) and correct the installation position.
10. If necessary, make temporary welds, and then check to confirm
that the closing and fit for windshield glass, door and fender are
correct.
11. MIG butt weld front side outer panel and front side outer panel
seams.
12. Reattach the cut away front side outer panel section, then MIG
butt weld.
13. MIG plug weld all holes and MIG butt weld all seams, in the front
side outer panel.
14. Clean and prepare all welds, remove all residue.
15. Apply body filler to joints and sand as needed.
16. Apply the two-part epoxy primer to the interior of the front side
outer panel.
PRO-0620
PRO-0630
PRO-0610
PRO-0640
92
BODY PANEL REPAIR PROCEDURE - Front side outer panel
17. Clean all welds with a disc grinder.
NOTE
1.
Be careful not to grind welded portions too much.
2.
The internal parts will be stronger if the weld traces are
not ground.
18. Before welding the front inner lower pillar panel, apply the two
part epoxy primer and anti-corrosion agent to the interior of the
fender apron panel.
19. Install the front inner lower pillar panel in place.
20. MIG plug weld all holes.
21. Clean and prepare all welds, remove all residue.
22. Apply an anti-corrosion agent to the welded parts and inside
of front inner upper pillar (Refer to the CORROSION PRO-
TECTION).
23. Prepare exterior surfaces for priming, using wax and grease
remover.
24. Apply metal conditioner and water rinse.
25. Apply conversion coating and water rinse.
PRO-0460
PRO-0660
PRO-0670
PRO-0690
PRO-0680
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