Body Repair Manual

Side Sill (Outer Panel)
Replacement (cont'd)
BULKHEAD
WHEEL ARCH
EXTENSION
INSIDE SILL
CENTER INNER
PILLAR
BULKHEAD
REINFORCEMENT
SIDE SILL
EXTENSION
CENTER PILLAR
STIFFENER
4. Mold the related parts.
Fill any holed areas by MIG or gas welding.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
Level and finish burrs at welded areas with a disc
sander, then even them out with a hammer and
dolly.
Sand off the undercoat from both sides of the flange
to be welded.
2.5TL:
NOTE: Check the damage of the honeycomb floors and if
necessary replace it (see page 4-58).
HONEYCOMB
FLOORS
5. Set the repair part.
Sand off the undercoat from both sides of the welded
flange on the repair part.
Clamp the repair part in place with vise-grips.
NOTE: Apply the spot sealer to the welding surface when
spot welding.
Check the body dimensions (see section 6).
6. Tack weld the repair part.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
REPAIR
PART
Remove the vise-grips and install the fender and
doors. Check for differences in level and clearance.
CENTER PILLAR
STIFFENER
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