Mitsubishi Evolution X. Manual — part 7

BODY REPAIR

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2. Align the silencer layer in the position where it is to be

installed, and then press it down with a roller or a block of
wood so that it adheres well.
NOTE: An infrared light can also be used to heat both the
silencer layer and the body panels (be sure to wear gloves).

POSITIONING DIMENSIONS FOR OPENINGS

M4090010000045

When replacing the panel of the opening of the front
pillar, center pillar and other openings, make a point
to securely bite the poltapower, etc. so the position of
the opening is not off-center. Upon assembling,
adjust the opening dimensions to the standard speci-
fications and then weld.

AB200099

AB200100

Porta power

AD

BODY REPAIR

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STANDARD PROCEDURES FOR SHEET METAL WORK

M4090012000030

REPAIRS USING A HAMMER AND DOLLY

It a damaged external panel, etc., can be reused, the
usual way to repair it is by using a hammer and dolly
to hammer out the damaged area. The following
describes these repair procedures.

.

1. Check whether or not there is foreign material (mud, etc.) on

the panel surface. If so, clean it away.

CAUTION

The surface of the hammer and dolly must be free of scars,
etc.
2. Select the appropriate hammer and dolly to be used

according to the panel shape.

CAUTION

Care should be taken, as far as possible, not to permit the
panel plates to become elongated.
3. Use the hammer and dolly to repair the dents and other

uneven surfaces of the panel.

(1) First repair the larger areas of damage so that they are as

close as possible to the original condition before the
damage occurred.

(2) Next repair the areas of moderate damage.
(3) Finally, smooth the surface out.

AB200101

(1)

(2)

(3)

BODY REPAIR

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CAUTION

• Be careful not to file too much; this will reduce the

strength and rigidity of the panel.

• Do not use the file in one direction only; alternate use

in two directions diagonally opposite each other.

4. Next, file the area so that convex and concave parts are no

longer clearly visible, and at the same time remove small
projections.

5. After once again smoothing the clearly visible dents and

projections by using the hammer and dolly, follow step 4
above.
Alternately repeat hammering and filing until there are file
traces over the entire repair area.

6. Make a solder build-up at the repair.
7. Finally, finish up the solder build-up using a body file.

USING A FRAME STRAIGHTENER

M4090013000044

For serious and extensive damage, when for exam-
ple the damage extends to the frame of members, it
is necessary to first use a frame straightener to make
a rough, overall repair of the body, and then to pro-
ceed to careful repairs of each individual area of
damage. When a frame straightener is used for body
repairs, it is a fundamental principle that the pulling
should be in the direction from which the impact was
sustained, and from the opposite direction. If this is,
in error, not done, previously undamaged compo-
nents will be deformed, and repair may become
impossible.
It is for that reason that it is important to decide upon
the method of repair, especially regarding the initial
overall repair, by following the steps below.

OVERALL ROUGH REPAIRS

1. First, analyze the impact. This means analysis

and consideration of the point of collision, the
speed at the time of collision, and the strength,
weight and shape of the object hit.

2. Then get a complete understanding of the

condition of the existing damage. In particular, if
the damage extends to the suspension installation
components, an inspection must be made to
determine whether or not there is any deviation of
the frame or body alignment.

3. Finally, determine what repair methods should be

used.

• To what extent will frame straightening and other

overall repairs be necessary in order to restore
the damaged areas to the way they were?

• At what stage of the repairs should panels adjoin-

ing the components to be frame straightened,
etc., be removed?

• Decide upon the work steps and restoration

methods to be followed after the rough, overall
repairs are completed.

Select the frame straightener based upon the results
of above, and use it to pull in the appropriate direc-
tion. More than one direction may be appropriate,
depending upon the damage.
If the damage is of a moderate degree or less, it may
be possible to do all that is necessary in one pull.
If, however, the damage is major, that is to say if
repairs must be made to components of the passen-
ger compartment such as the dash panel, etc., it may
be necessary, after completing the first pull, to set up
the frame straightener at a different position and use
it again at that position.

AB200102

BODY REPAIR

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FRAME STRAIGHTENING NOTES

• For safety, no one must be standing in the direction of the

pull.

• Wires or chains should be used for protection in the event

of an accident.

• For frame straightening of body with frame, care should be

taken regarding the position (body mount) of installation to
the frame. The reason for this is that usually mounting rub-
ber pieces are used at the installation part in order to
improve vibration prevention, and these mounting rubber
pieces might be deformed if there is a deviation of the
installation position.

• If the part to be pulled is made of high-tensile steel (which

has a higher tensional strength and yield point than ordinary
steel), the pulling must be done with care in order to avoid
"over pull" and "spring back". It is particularly important for
the pulling of sidemembers and other reinforcement compo-
nents made of high-tensile steel that the pulling not be all
done at one time; pull gradually while using a hammer to
repair distorted areas as the pulling is done.

FRAME REPAIR PROCEDURES

M4090014000047

The frame is subjected to the following types of
loads.

• Vertical loads: Vertical loads may occur either

while stopped or during travel.

• Lateral (horizontal) loads: This type of loads

occurs during turning, start-off and braking.

• Torsional loads: Torsional loads occur while trav-

eling on roads with poor surface conditions.

These various types of loads are compounded under
various conditions, and are applied to the frame.
As a result, it is important, before attempting to repair
the frame, to carefully observe the shape of the dam-
aged part and to in that way fully understand the
cause of the damage.

CHECKING FOR FRAME CRACKING OR
FLAKING

Check, by using a test hammer, for flaking or cracking of the
welded surface of the sidemembers, crossmembers and brack-
ets.

REPAIRING CRACKS

If the check reveals a crack(s) in the frame, repair as described
bellow.

AB200103AD

Wires for
protection

AB200127AD

Test hammer

Sidemember