Partial replacement of body elements (Freelander 2)

The procedure for partial replacement is the same as in the "Welded elements" section.

The main difference between partial replacement of elements and complete replacement is the preparation of butt and overlap seams.

• When cutting body parts, care should be taken to properly remove paint and zinc coating on internal areas. This applies primarily to hard-to-reach internal areas.
• To ensure the quality of the weld, it is important that the inner surface is cleaned down to the metal. Zinc and paint residues in the weld area burn off and cause porosity during welding.
• If the zinc layer and paint coating are not removed, the zinc and paint will burn during the welding process. The resulting soot prevents proper protection of the cavity.

Procedure

Within 30 mm of the weld, the paint must be removed using 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 weld.

NOTE: If space is limited, a flat scraper or wire brush may be used instead of a rotary brush. Do not use an angle grinder, which will weaken the structure.

Applying a wax coating to protect the cavities on the door threshold after partial repair:

Pos.	Spare part number	Name
1	-	Welding bead
2	-	Spray head
3	-	Remote element
4	-	Spray

Classification of various corrosion protection measures for dent removal

Corrosion protection method	External surfaces	Accessible internal surfaces	Inaccessible internal 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 grinding	Welding flange available	Inaccessible weld flange
Welding primer	X
Coloring		X	X
Flange Sealant			X
Cavity Protector				X