Hyundai i30 / Elantra Neos. Body repair manual - part 28

BODY PANEL REPAIR PROCEDURE

BP-51

LOWER QUARTER PANEL

BFDBP6601G

WELDING POINTS

270mm

50mm

Laser welding

MIG plug welding

MIG butt welding

MIG lap welding

BP-52

BODY  PANEL REPAIR PROCEDURE

REMOVAL

1.

Depending on the extent of damage, measure and mark
cutlines on the quarter outer panel as indicated in the
illustration.

2.

Cut the quarter outer panel along the cutlines and
remove the quarter outer panel as illustration.

When cutting the quarter outer panel, be careful not to
cut quarter inner panel.

NOTE

3.

Drill out all attaching spotwelds and laser weld on the
quarter outer panel, including the seam around the door
lip opening.

4.

Remove the quarter outer panel.

5.

Clean cut portions with a disc grinder.

BFDBP6718

270mm

50mm

BEDBP6606

BFDBP6601H

BFDBP6601I

BFDBP6601J

BODY PANEL REPAIR PROCEDURE

BP-53

6.

 After removing, apply the welding primer.

INSTALLATION

1.

Transcribe the cutlines to the new quarter outer panel,
adding 30 mm overlap each end.

2.

Drill 8 mm holes in overlap areas and along upper and
lower flanges of the new quarter outer panel for MIG
plug welding.

BFDBP6720B

3.

Apply body filler to the welded seam. Sand and finish.
Apply the two-part epoxy primer to the interior of the
quarter outer panel.

4.

Fit and clamp the quarter outer panel in place.

5.

Measure each measurement point (Refer to the  BODY
DIMENSIONS) and correct the installation position.

6.

MIG plug weld all holes and MIG butt weld seams.

BFDBP6721

BFDBP6717A

BFDBP6717B

BP-54

BODY  PANEL REPAIR PROCEDURE

7.

Clean and prepare all welds, remove all residue.

8.

Apply an anti-corrosion agent to the welded parts and
interior of the quarter outer panel (Refer to the
CORROSION PROTECTION).

9.

Prepare exterior surfaces for priming, using wax and
grease remover.

10. Apply metal conditioner and water rinse.

11.  Apply conversion coating and water rinse.

12. Apply the two-part epoxy primer.

BFDBP6717C

BFDBP6717D