Hyundai H1: Body Repair Manual - part 26

106

REMOVAL

1.

Depending on the extent of damage, measure and mark cutline
on the quarter outer panel 205 mm downward from the quarter
window RH glass upper line as illustration.

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

2.

Measure and mark cutline on the quarter outer panel 150 mm
upward from the quarter window glass RH lower line as illustra-
tion.

3.

Drill out all spotwelds attaching the quarter outer panel to the
inner panel below cutlines.

4.

Cut quarter outer panel along cutlines to remove quarter outer
panel.

NOTE
1) Becareful not to cut quarter inner panel.

QSAQ2270

QSAQ2280

QSAQ2290

QSAQ2300

150 mm

205 mm

107

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

2) When cutting "C" outer pillar (Right side), be careful not
    to cut reinforcement panel as illustration.

QSAQ2310

5.

Remove quarter outer panel.

6.

Prepare all surfaces to be welded.

QSAQ2320

QSAQ2330

108

INSTALLATION

1.

Measure and mark guide lines 30 mm upward and downward
from "C" pillar outer panel and "D" pillar outer panel cutlines.

2.

Drill 8 mm holes where the insertion panel to be installed.

3.

Make an insertion panel with 60 mm width from unused portion
of the panel.

4.

Fit and clamp the insertion panel in place for welding.

5.

Mig plug weld the insertion panel.

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

8.

Apply a coating of silicon rubber sealer and body sealant at
places indicated in the illustration.

QSAQ2360

QSAQ2280

QSAQ2281

QSAQ2321

6.

Transcribe the cutline to the new quarter outer panel, cut to
length and chamfer butt end to improve weld surface.

7.

Drill 8 mm holes in production locations along outer panel
flanges and insertion panel for attachment to other panels.

Insertion
panel

60 mm

60 mm

Insertion
panel

109

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

9.

Fit and clamp the quarter outer panel in place.

10. MIG plug weld all holes and MIG butt weld seams. Spot weld at

the wheel well.

NOTE
In order to prevent distortion caused by the welding heat,
make the welds alternately at regular intervals.

11. Clean and prepare all welds, removing all residue.

12. Apply body filler to the welded seam, sand and finish.
13. Apply the two-part epoxy primer to the interior of the quarter of

the quarter outer panel.

14. Apply anti-corrosion agent to the welded parts and interior of the

quarter outer panel (Refer to the CORROSION PROTECTION).

15. Prepare exterior surfaces for priming, using wax and grease

remover.

16. Apply metal conditioner and water rinse.
17. Apply conversion coating and water rinse.
18. Apply the two-part epoxy primer.

QSAQ2390

QSAQ2400

QSAQ2410

QSAQ2280

19. Apply the correct seam sealer to all joints.
20. Reprime over the seam sealer to complete the repair.

(Refer to the BODY SEALING LOCATIONS).

60 mm

Insertion
panel