C4GB08F1 - 307

FOREWORD STRUCTURE

The body repair methods have been studied to enable the repairer to perform quality work in the best possible conditions .

1 - THE MAIN OPERATIONS ARE BROKEN DOWN UNDER THE FOLLOWING HEADINGS

1 - 1 - COMPLEMENTARY OPERATION(S)

All the operations which must be performed in addition to the actual repair .

1 - 2 - IDENTIFICATION OF REPLACEMENT PARTS

All the parts to be ordered for the actual repair .

1 - 3 - COMPOSITION

Identification of the composition of all of the parts ordered .

1 - 4 - PART(S) REQUIRED TO CARRY OUT THE OPERATION

Identification of the actual repair parts after cutting or removing certain components .

1 - 5 - PREPARATION OF NEW PARTS

Descaling of mating edges before welding .

Definition of drilling or cutting of components for partial replacement .

1 - 6 - CUTTING OUT

To be performed on the damaged components as indicated .

1 - 7 - SEPARATING

Rectifying, flattening and disking the mating edges .

Application of welding primer to the mating edges (on both body shell and new components) .

1 - 8 - ADJUSTMENT

Offering up components for alignment .

Check .

Adjustment .

1 - 9 - WELDING

Welding on the lines provided using appropriate equipment .

1 - 10 - FINISHING

Loading of surfaces which require careful finishing .

1 - 11 - SEALING

Application of mastic as indicated .

1 - 12 - PROTECTION

Application of anti-chip compound to the areas indicated .

Spraying liquid wax into box members .

1 - 13 - FOAM OPERATION

Injection of expanding foam into the areas indicated .

IMPERATIVE : on completion of the work: check the operation of electrical equipment, check the closing of movable panels, clean off all marks .

2 - WELDING

All the new models produced will have improved quality thicker panels, and at least 95 % of them will be galvanised on both sides, with a 12 year anti-corrosion warranty .

This involves certain constraints of installation and resistance welding equipment, as follows :

• supply voltage ; 400 v three-phase
• fuse protection ; 32 a delayed
• compressed air supply: 6 bars min / workstation with purifiying pressure relief valve (lubricated or otherwise)
• powerful welding unit saitek invetex z-1 - (sai 11.s0) ; powerful welding equipment CAR-O-LINER PR8 (CAR 11.T9)
• curve circuit breaker D

THE MODELS MANUFACTURED HAVE WELDS CREATED USING A SOLDERING TECHNIQUE BY MEANS OF THE MIG PROCESS .

3 - REMINDERS ABOUT WELDING

3 - 1 - VOLTAGE DROPS

In order to avoid voltage drops involving poor resistance of the weld spot concerned, never have overloaded lines, an inadequate wire diameter and supply sockets sited too far from the circuit breaker .

An under-supplied machine, even if highly efficient, cannot guarantee acceptable welding .

In order to guarantee a correct supply to the welding stations, it is absolutely essential to have a line with wires of 6 mm2 or 10 mm2 if more than 50 m .

Maintenance of the line ; Check and re-tighten all the connections, sockets and connection boxes .

3 - 2 - PRINCIPLE OF RESISTANCE WELDING

This consists in obtaining a fusion core with a diameter specified in terms of the thickness of the panels .

Electrical resistance welding uses the release of heat produced by a high current passing through and requires the application of a load between the parts to be welded .

A = Fused core .

B = Top electrode .

C = Bottom electrode .

D = Parts to be welded .

WARNING : welding a single surface (so-called core sample welding) is not a reliable procedure; it should not be used in body repair .

3 - 3 - DIAMETER OF ELECTRODE POINTS

The choice of electrode points varies depending on the thickness of the panels to be assembled (Diameter = Thickness X 2 +3 mm) .

3 - 4 - SETTING OF ELECTRODE HOLDERS

Select electrode holders in such a way as they permit the passage of the clamp, while being as short as possible .

Incorrect adjustment would risk distorting or perforating the panels and having a spot weld of insufficient strength .

The electrodes must be :

• aligned
• correctly ground
• not have turned blue (an annealed electrode is a very poor conductor and cannot make a correct weld spot)

E =Correct .

F =Incorrect .

3 - 5 - STRENGTH OF THE WELD SPOT

Diameter A =Diameter of the core .

Before welding, carry out tests on sample panels which are identical and in the same order as those to be welded .

Check the strength of the weld spots, in order to determine the current and pressure necessary to obtain good quality (too low a current or pressure gives a spot that is stuck and not welded) .

When removing spot welds (by extracting with pliers) the formed core remains on one of the panels (the thickest) and produces one hole on top of the other .

A spot weld is incorrect if :

• there is no core when removed (in this case the spot is stuck and not welded)
• the diameter of the core is less than the minimum figure required

The removed spots (cores) have a diameter of 4 mm for a reference panel less than 1.5 mm thick, and diameter 6 mm for a reference panel from 1.5 mm .

The diameter is measured at the base of the core after separation of the panels and is determined acccording to the reference panel .

3 - 6 - QUALITY OF WELD SPOT

The elements determining the quality of the weld spot are :

• the cleanness of the parts
• sufficiently long lining-up of parts time
• the current strength
• the time for the current to pass through
• the tightening load of the panels
• the forging (cooling time during tightening)
• the diameter of the electrode points
• the straightness of the clamp / panels
• the spacing of the spots (cooling of the machine)

Visual check of the weld spot .

This consists in checking that the points :

• are not burned, not perforated and are free of splinters
• have a slight indentation (recess of 0.2 to 0.4 mm depth) on both surfaces of the panels for standard spots
• are free of indents on the front surface in the event of a flat ground electrode being used
• do not cause distortion of the panels

3 - 7 - WELDING ; MIG PROCESS SOLDERING

The melting of the filler metal intended to guarantee assembly is produced solely by the heat of the electric arc established and maintained between a consumable electrode wire and the part .

The protective gas used is inert and does not contribute to the melting .

The filler wire and the base metal are different in nature; this is a heterogeneous assembly in which the filler product bonds by liquid effect onto the support which is not melted .

There is no dilution between the two materials nor are there any metallurgical changes .

Metals welded: soft steel .

Fillers used: copper-based wire, copper-aluminium, copper-tin or copper-silicon at 3 Diameter 0.8 1 and 1.2 .

NOTE : this vehicle has been designed using the mig brazing process technique ; if a connection has been welded using this process, the use of another process is strictly prohibited .

3 - 8 - PROTECTION

WARNING : in order to avoid any future problem after repair or replacement of a panel part, ensure there is satisfactory protection of the various surfaces; this is to obtain characteristics identical to the original, ensuring the quality of the repair warranty against corrosion .

IMPERATIVE : using an approved weldable primer between the panels to be assembled .

3 - 9 - SAFETY

Observe the safety and fire rules .

For welding galvanised panel parts, work in a ventilated area .

Coat the equipment with individual appropriate protection .

4 - CORROSION PROTECTION

IMPERATIVE : in order to adhere to the 12 year anti-corrosion warranty, observe the following recommendations .

4 - 1 - SURFACE TREATMENT

WARNING : the operation starts after structural work on bare metal .

Adequate sanding of the welded joining areas (rear quarter panel, flange area,....) .

Degreasing with solvent of the surfaces to be treated in order to make them ready to receive the electro-zinc plated protection .

To carry out the electro-zinc plating operation, a deposit of is required, corresponding to the initial treatment by the manufacturer .

Rinse the treated surfaces with water .

Super finish sanding with abrasive pad .

Wipe ; Dry .

WARNING : do not touch treated surfaces with bare hands .

4 - 2 - APPLICATION OF UNDERCOATS (SURFACE WITH DISTORTION)

Application of a special zinc polyester mastic .

Sanding .

If necessary ; Finishing mastic .

Sanding .

Application of a primer in the area to which the mastic has been applied .

Application of a two-part compound primer over the whole of the repaired area .

Stoving 30 minutes at 60 ° c .

Allow it to cool .

Sanding ; Wipe .

ReminderUse approved equipment for re-applying zinc plating .

4 - 3 - APPLICATION OF UNDERCOATS (SURFACE WITHOUT DISTORTION )

Application of a primer on a zinc-plated surface .

Application of a two-part compound primer over the whole of the repaired area .

Stoving 30 minutes at 60 ° c .

Allow it to cool .

Sanding ; Wipe .

ReminderUse approved equipment for re-applying zinc plating .

4 - 4 - SEALING

Apply sealing seams (e.g: wing / door junction flange area) .

Underbody underseal .

Dry .

4 - 5 - FOAM OPERATION

Injection of expanding foam into the areas indicated .

4 - 6 - PAINT

Carry out normal paint procedure .

Stoving 30 minutes at 60 ° c .

Allow to cool and inject wax into hollow areas, making sure that the areas adversely affected by the weld are uniformly covered with wax .