Hyundai i30 / Elantra Neos. Body repair manual - part 17

BODY PANEL REPAIR PROCEDURE

BP-7

REPLACING BODY PANEL

REMOVAL

1.

Body measurement
a)

Before removing, measure the damaged area
according to the dimensions supplied in Body
Dimension, section BD. If deformation is present,
use a frame straightener to adjust.

b)

When removing a panel, apply clamps to prevent
damage of each part, and support the lower end
of the frame to prevent deformation during the
procedure.

2.

Cut and welding point selection
Cutting, if necessary, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.

3.

Cutting rough area for replacement part
Cutting should be done according to the following steps
to make removal easy:
a)

Use care when cutting an area close to a pipe or
wiring harness.

b)

Cut an area leaving 30~50 mm of tolerance.

4.

Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.

BVQBP6011

Reinforcement

Reinforcement

Cut area

BVQBP6012

BVQBP6013

BFDBP6601K

BP-8

BODY  PANEL REPAIR PROCEDURE

5.

Determine a cutting method
a)

Cutting a spot welded area
Make a hole in the middle of spot welded area
with a punch, remove welded area using a spot
cutter and remove using a chisel.

b)

Removing brazed area
Remove using a torch and wire brush, and chisel.

c)

Removing arc welded area
Remove plug welded area using a disk grinder
and chisel.

BVQBP6014

BVQBP6016

BFDBP6015

BODY PANEL REPAIR PROCEDURE

BP-9

4.

Preparation for spot welding
Remove paint on spot welded area and on the area
overlapped by the new part using a belt sander or
similar tool.

5.

Drilling a hole for plug welding
If the thickness of the part to be welded is less than 3
mm, drill a 5~6 mm diameter hole. If the thickness of
the part to be welded is greater than 3 mm, drill a hole
using a 7 mm diameter drill.

NOTE

Do not spot weld where thickness is greater than
3 mm.

PREPARATION FOR INSTALLATION

1.

Spot weld finish
Use a disk grinder or similar tool to finish spot weld
mark, Do not grind more than is necessary to smooth
surface.

2.

Panel preparation
Repair any bent or uneven areas with a hammer to
improve the installation process.

3.

Cutting a rough area for a new part
When rough cutting an area for a new part, leave a
tolerance of 30~50 mm.

BVQBP6017

BVQBP6020

BVQBP6021

BFDBP6018

BFDBP6608

BP-10

BODY  PANEL REPAIR PROCEDURE

INSTALLATION

1.

Checking welding and fitting in advance
a)

When installing a new par t, measure the
dimensions of each part according to the body
dimensions given in Section BD, and set part to
the reference dimensions.

b)

Prior to final welding, check the fit of all related
parts.

2. Selecting number of welding points

Spot welding : Multiply the original number of

        factory welds by 1.3 times

Plug welding : Same number as original number

       of factory welds

NOTE

•

Plug welding should be done using a carbon arc
welding machine.

•

Brazing should be done only on areas that were
originally brazed at the factory.

3.

Caution when spot welding
a)

Do a test welding on a piece of material of the
same type and thickness as the part to be welded
and proceed if test weld is good.

b)

Before spot welding, check if welding debris, oil
or paint is present on the area where surfaces
meet.
Clean or sand as necessary.

BVQBP6024

3mm

Spot welding:initial number of welds x1.3

Plug welding-used when
spot welding is not
feasible or material is
thicker than 3 mm 

Welding points-same number as original number of factory welds.

Initial welding

pitch:50 mm

Welding after repair

pitch:35 mm

BVQBP6025

Center

diameter

3 mm 

Using a test piece

Using a hammer

and a chisel

Nugget
diameter:
4/5 of tip 

BFDBP6022

BFDBP6601B