Body Repair Manual

Rear Side Outer Panel
Replacement (cont'd)
OUTER
PANEL
REAR PARCEL
SHELF
TRUNK GUTTER
REAR
PANEL
4. Mold the inner panel and related parts.
• Fill and holes drilled 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, etc. with a disc sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
REAR DAMPER
SEPARATOR
REAR
DAMPER
STIFFENER
Apply the mastic sealer.
REAR PANEL
WHEEL
ARCH
EXTENSION
REAR FLOOR
SIDE SILL
EXTENSION
5. Cut the replacement part.
• Cut so that the repair part overlaps the side sill by 30
mm (1.2 in).
• Apply body paint to the back of the repair part.
• See Paint Repair section.
• Ventilate when spraying paint. Most paint
contains substances that are harmful if inhaled
or swallowed. Read the paint label before
opening the paint container.
• Avoid contact with skin. Wear an approved
respirator, gloves, eye protection and appropriate
clothing when painting.
• Paint is flammable. Store it in a safe place, and
keep it away from sparks, flames or cigarettes.
• Remove the undercoat from both sides of the weld
flange with a sander to expose the steel plate.
INNER PANEL
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