Body Repair Manual

Front Bulkhead
Replacement (cont'd)
5. Mold the damaged related parts.
• Use a hammer and dolly to mold the damaged areas
of the front wheelhouse front and side frame.
• Even out the welding flanges with a hammer and
dolly.
• Fill all drilled holes by MIG or gas welding.
2.5TL:
FRONT WHEEL-
HOUSE
FRONT SIDE FRAME
3.2TL:
FRONT
WHEEL-
HOUSE
FRONT SIDE
FRAME
6. Set the new front bulkhead.
• Grind both sides of the welding section of the bulk-
head with a sander to remove the undercoat and
expose the steel plate.
U^^JQQ To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
• Clamp both the right and left sides with the vise-
grips as shown.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Check the front bulkhead position using the body
dimensional drawings (see section 6).
7. Tack weld the new front bulkhead.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
Spot weld the clamped sections.
NOTE: Make sure that the right and left bulkheads are
in line with each other.
8. Measure the front compartment diagonally.
Measure the front compartment diagonally with a track-
ing gauge or convex tool as shown to check it for
twisting or bending.
9. Temporarily assemble the hood, headlight and front
fender, then check the clearances and level differences.
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