The main difference between a partial replacement of elements and a complete replacement is the preparation of butt and overlap joints.
- When cutting body parts, care must be taken to properly remove paint and zinc coating on interior areas. This primarily applies to hard-to-reach interior areas.
- To ensure the quality of the weld, it is important that the inside surface be cleaned down to metal. Zinc and paint residues in the weld seam burn out and cause porosity during welding.
- If the zinc layer and paintwork is not removed, the zinc and paint will burn during the welding process. The resulting soot prevents proper cavity protection.
Procedure
Within 30 mm of the weld, paint should be removed with a rotating wire brush. This operation should be performed on both new and old body parts. Depending on the body element, the zinc coating layer must be removed within 10 mm of the welding seam.
NOTE: If space is limited, a flat squeegee or wire brush can be used instead of the rotating brush. Do not use an angle grinder that weakens the structure.
Application of cavity protection wax on door sill after partial repair:
Pos. | spare part no | Name |
1 | - | Weld bead |
2 | - | spray head |
3 | - | remote element |
4 | - | Spray |
Classification of various corrosion protection measures for dent removal
Corrosion protection method | External surfaces | Available interior surfaces | Inaccessible interior surfaces |
Coloring | X | X | |
Cavity Protector | X |
Classification of various methods of corrosion protection when installing new elements
Corrosion protection method | Welded flanges before welding in place (contact surfaces) | All surfaces cleaned by sanding | Available Weld Flange | Inaccessible weld flange |
Welding primer | X | |||
Coloring | X | X | ||
Flange Sealant | X | |||
Cavity Protector | X |
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