Discovery 2. Manual — part 264

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.

PANEL REPAIRS

PROCEDURES 77-2-19

3. Use a resistance spot welder where access

permits. Try to ensure weld quality by using a
welding monitor where possible.

4. MIG tack weld butt joints and re-check

alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.

5. Dress MIG tack welds using a sander with 36

grit disc, or a belt-type sander where access is
limited.

6. MIG seam weld butt joints.

PANEL REPAIRS

77-2-20 PROCEDURES

7. Always use MIG plug welds where excessive

metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose.

8. Dress all welds using either a sander with 36

grit disc, or a belt-type sander and/or
impregnated wire brush.

NOTE: Brazing operations, if required, must be
carried out at this point.