Frelander 2. Manual — part 672

9. Mill out the spot welds.

10. NOTE: Ensure there is a 50mm minimum stagger between

the butt joints.

Saw cut the old panel at the points illustrated, using the new

panel for reference, ensuring that the new panel overlaps.

11. Separate the joints and remove the old panel, also releasing

the NVH elements.

Installation

1. Prepare the new panel in the areas where it is not fully

welded and spot weld.

2. Prepare the old and new panel joint surfaces.

3. Drill holes in the new panel ready for MIG plug welding.

4. Offer up the new panel and clamp into position. Check

alignment, if correct, proceed to next step, if not, rectify and

recheck before proceeding.

5. Remove the new panel.

6. Apply adhesive to the areas illustrated.

7. If necessary, renew the NVH element(s).
8. Apply sealer adhesive to the NVH elements.
9. Offer up the new panel and clamp into position.

10. With panels clamped into position, tack weld the butt

joints.

11. Dress the tack welds.

12. MIG weld the butt joints.

13. MIG plug weld.