Car protection
1. Cover the seats before performing any procedures to prevent contamination.
2. Cover all windows, seats and mats with heat resistant material when welding.
3. Protect moldings, seals and body trim.
Welding
Observe the following conditions when carrying out welding work:
1. Wear appropriate eye protection.
2. Strictly follow the instructions for use of welding machines supplied by the manufacturer.
3. Do not weld, smoke, or use open flames near volatile chemicals, cleaners, or solvents, or near areas where they have been applied.
Frame Straightener
When using the frame straightening tool, observe the necessary safety rules, do not approach the body straightening area with the tool chain.
Electrical components
1. Before removing and inspecting electrical parts or before starting electric welding, disconnect the negative battery terminal.
2. Do not expose control boxes to temperatures above 80°C.
Note: If it is likely that the ambient temperature will reach 80°C or more, remove the control units from the vehicle before starting work.
3. Be careful not to drop the control boxes or get hit.
4. When disconnecting electrical connectors, do not pull on the wires, but hold on to the connector housing.
5. When connecting, insert the connector until it clicks into place.
For best results
Disassembly
Before starting work on disassembling and repairing the body, measure the size of the damaged area. If the body is deformed, correct its dimensions with a special straightening stand.
Choose the most easily accessible area for cutting, which is the least prone to deformation during welding. Work the area in such a way that it allows the new part to be overlaid with an overlap of 30 - 50 mm.
Secure the body with clamps and jacks to prevent damage to the body when working on it.
Removing individual parts
Be careful when removing moldings and facings from the machined surface of the body. Apply adhesive tape to the areas where you want to prevent damage to the removed part or vehicle body. Before carrying out work, check the presence of pipelines, hoses or electrical wiring in the vicinity of the damaged area.
Assembly preparation
1. Remove paint from the surface of the new part and body to apply sealant, then apply sealant to seal.
2. If the thickness of the area to be welded with the overlay panel is more than 3mm, it is necessary to use a carbon dioxide arc welder.
3. Fix the body with clamps and jacks to prevent damage to the body when working with it.
4. Drill holes with a diameter of approximately 5-6 mm in places not suitable for spot welding.
5. The new part should overlap the repaired area, and the overlap should be 30-50 mm.
Assembly
When installing a new part, make sure that the body dimensions are observed. Start welding after checking for clearance between adjacent parts.
The amount of spot welding should be selected according to the following criteria:
Attention.
- The gap between the electrodes of the spot welding machine should not exceed 3 mm, since this significantly affects the strength of the welding current. If possible, the new weld point should be placed between existing points.
- Before and after spot welding, it is necessary to perform a test welding of the same material as the body panels and check the reliability of the welding.
Anti-corrosion treatment and sealing after assembly
Apply sealant to the car body where necessary. Apply anti-corrosion material (wax, oil) for welding areas. Where necessary, apply primer to body surfaces.