Mitsubishi Evolution X. Manual — part 5
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-17
CAUTION
Perform the operations carefully so that the cut ends fit
together properly.
11.Cutting of new parts by using a measurement marking
If overlap cutting is not possible in a place where butt
welding is to be done, make a measurement marking on the
new part at the exact same measurement which was used
for the cutting of the body panel, and then cut the new part
by using this measurement marking.
• Two-layer construction
When cutting a front pillar or center pillar which has a
two-layer construction but no reinforcement, make the cut-
ting of the inner panel and that of the outer panel approxi-
mately 50 mm (1.97 inches) apart in order to obtain
maximum strength.
• Three-layer construction
When cutting a front pillar or center pillar which has a
three-layer (including a reinforcement) construction (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the
reinforcement. If the inner panel is an assembly replace-
ment part, cut it at two places in order to provide ample
working space for the butt welding of the reinforcement.
12.Application of spot sealer to spot-welded points
Apply an electro-conductive spot sealer to the connecting
surfaces of both the new parts and the vehicle body in order
to provide corrosion protection.
AB200062 AD
Outer panel
Approx. 50 mm
(1.97in)
Inner panel
Twolayer construction
AB200063AD
Inner panel
Inner panel
cut line
Inner panel cut line
Outer panel
and reinforce-
ment cut line
Three-layer construction
AB200064
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-18
CAUTION
During temporary mounting, it is extremely important to
obtain accurate measurements for each component. The
mounting positions for the front and rear suspensions are
especially crucial with regard to safety; therefore, it is nec-
essary that all work concerning these areas be done care-
fully and correctly.
13.Temporary mounting of new parts
(1) In order to bring the new parts into the proper mounting
position, measure each part carefully and make any
corrections necessary in order to obtain agreement with
the measurements.
(2) In addition, make temporary welds, and then check to
confirm that the closing and fit of the doors, fenders, etc.,
are correct.
For parts which should be symmetrical to the body
center, measure the distances from the body center point
to both the left part and the right part, and confirm that the
distances are the same.
CAUTION
Weld completely so that there are no pinholes.
14.Butt welding
For burr welding, make a 10
− 15 mm (0.39 − 0.59 inch) MIG
spot weld, and then, in order to prevent warping which might
be caused by the welding heat, complete the welding by
making welds of the specified width at alternate positions.
AB200065
AB200066
AB200067
AB200068
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-19
15.Spot welding
When doing spot welding, it is not only important to correctly
position the electrode tips, but also to hold the two panels
securely together with vise-grip pliers or some other type of
clamps, being sure that they are in perfect contact with each
other.
• Be sure that the force applied by the arm is sufficient.
• Use a test piece to check the secondary current and the
current application time of the spot welder, and adjust the
values as appropriate.
16.Plug welding
If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5
− 6 mm (0.2 − 0.24 inch) in diameter. In
addition, be sure the two surfaces are in complete contact
with each other by using vise-grip pliers to securely hold
them.
NOTE: Depending on the working conditions, it might also
be necessary to make holes in the panel remaining on the
body
17.Hemming (Adhesion type)
(1) Apply an adhesive to the area to be hemmed of the door
outer panel.
(2) For the area to be hemmed of the door outer panel, apply
an adhesive and smooth the panel with a hammer and a
dolly. Then, hem the panel with a hemming tool.
AB200070
AB200070
AB500010
AB401282
A
Section
AD
AB500010
AB401282
A
A – A
AB200072AD
Hemming tool
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-20
18.Hemming (Welded type)
(1) For the area to be hemmed of the door outer panel, etc.,
smooth the panel with a hammer and a dolly, and hem it
with a hemming tool.
(2) After completing the hemming work, make MIG spot
welds at 50
− 60 mm (1.97 − 2.36 inches) intervals on the
inside.
CAUTION
Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.
19.Finishing work for butt welding and plug welding
Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.
20.Application of body sealant
Apply a coating of sealant carefully, without breaks, as
described in the section (of the manual corresponding to
that model).
NOTE: After application has been made to any external sur-
faces, perform smooth-finishing work.
AB200072AD
Hemming tool
AB200073
AB200074
AB200076
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