Freelander Body Repair Manual — part 65
PANEL REPAIRS
PROCEDURES
3
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
4
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
shaping block and hammer.
PANEL REPAIRS
PROCEDURES
5
Prepare new surfaces
1. Mark out bulk of new panel and trim to size,
leaving approximately 50mm overlap with
existing panel. Offer up new panel/section,
align with associated panels (e.g. new rear
quarter aligned with door and tailgate). 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
6
PROCEDURES
5. Apply seam sealer or structural adhesive, as
applicable, to panel joint surfaces.
See
INFORMATION, Sealing and corrosion
protection.
Offer up and align
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
300mm in length.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
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.
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