Discovery 2. Manual — part 682

PANEL REPAIRS

PROCEDURES 77-2-15

PROCEDURES

Panel replacement procedure

This procedure is designed to explain the basic panel
removal and replacement method. The main criterion
in removal and replacement of body panels is that
the original standard is maintained as far as possible.
While individual repairs will differ in detail, this
procedure has been devised placing emphasis on
ease of repair and the elimination of unnecessary
work.

Body panels are being increasingly manufactured in
high strength steels to meet design requirements for
safety and weight saving. As panels in high strength
steels cannot be visually identified, and as they are
more sensitive to excess heat than panels
manufactured from low carbon steel, it is advisable
that the following procedure be observed at all times.

Remove panel

1. Expose resistance spot welds. For those spot

welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.

NOTE: In wheel arch areas it may be necessary
to soften underbody coating, using a hot air
gun, prior to exposing spot welds.

2. Cut out welds using a cobalt drill.

3. Alternatively, use a clamp-type spot weld

remover.

PANEL REPAIRS

77-2-16 PROCEDURES

4. Cut away the bulk of the panel as necessary

using an air saw.

NOTE: On certain panel joints MIG welds and
braze should be removed using a sander where
possible, before cutting out the panel bulk.

5. Separate spot welded joints and remove panel

remnants using hammer, bolster chisel and
pincers.

Prepare old surfaces

1. Remove any remaining sealant using a hot air

gun to minimise the risk of toxic fumes caused
by heat generated during welding.

CAUTION: Care must be taken to avoid
excessive heat build-up when using the hot
air gun.

2. Clean all panel joint edges to a bright smooth

finish, using a belt-type sander.

NOTE: As an alternative, a disc sander may be
used.

3. Straighten existing panel joint edges using a

shaping block and hammer.

PANEL REPAIRS

PROCEDURES 77-2-17

Prepare new surfaces

1. Mark out bulk of new panel and trim to size,

leaving approximately 50 mm (1.968 in) overlap
with existing panel. Offer up new panel/section,
align with associated panels (e.g. new body
side panel aligned with door and taildoor).
Clamp into position.

2. Cut new and existing panels as necessary to

form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.

3. Prepare new panel joint edges for welding by

sanding to a bright finish. This must include
inner as well as outer faces.

4. Apply suitable weld-through primer, to panel

joint surfaces to be welded, using brush or
aerosol can.

PANEL REPAIRS

77-2-18 PROCEDURES

5. Apply correct sealant or adhesive, as

applicable, to panel joint surfaces.

+

CORROSION PREVENTION AND

SEALING, SEALING, Body Sealing.

Offer up and align

1. Offer up new panel and align with associated

panels. Clamp into position using welding
clamps or Mole grips. Where a joggle or brace
joint is being adopted, make a set in the original
panel joint edge or insert a brace behind the
joint.

NOTE: In cases where access for welding
clamps is difficult, it may be necessary to use
tack welds.

Welding

1. Select arms for resistance spot welding and

shape electrode tips using a tip trimmer.

CAUTION: Use arms not exceeding 300 mm
(11.81 in) in length.

NOTE: To maintain weld efficiency, the tips will
require regular cleaning and dressing.

2. Fit resistance spot welding arms and test

equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.