Hyundai Elantra Neos / Hyundai i30. Manual - part 17

BP-4

BODY  PANEL REPAIR PROCEDURE

BVQBP6003

Center punch the middle(nugget) of the spot weld.

Otherwise,

Spot welded area can be removed from the body frame.

Spot welded area cannot be removed from the body 

frame.

This part will not be cut.

This part will be cut.

BODY PANEL REPAIR PROCEDURE

BP-5

SPOT WELDING

1.

Commercial spot welding machines do not perform as
well as the machines used in the manufacturing
process. When spot welding, increase the number of
spot welds by 30% (1.3 times the original number of
welds).

2.

When spot welding, weld in the middle of the joint.

•

Spot welding on the edge of the joint will reduce welding
strength.

BVQBP6005

BVQBP6006

Good

BVQBP6007

No good

INSTALLING A NEW BODY FRAME

The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of
plate, shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations.
Therefore, a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the
body.

DETERMINING A WELDING METHOD

It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body
be used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body components
other than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.

BVQBP6004

Welding

Symbol

Details

Spot welding

Oxygen-acetylene welding

Carbon arc welding
(Plug welding)

Not used

Use when spot welding cannot be done or spot welding is not necessary. 

The most reliable welding method
(provides high efficiency and quality of assembled part.)

BP-6

BODY  PANEL REPAIR PROCEDURE

CARBON ARC WELDING

In areas where spot welding is not suitable, do plug welding
using a carbon are welding machine.

1.

Clamp the parts to be welded together tightly. Do not
exceed 1 mm of space between parts. A tolerance
greater than 1 mm will reduce the strength of the
welded area.

2.

Weld in the middle of the flange joint.
a)

Drill a hole 5~6 mm on one side of the flange
only, and weld within the hole.

b)

Do not weld on the edge of the flange joint.

BVQBP6008

1mm

Maximum

tolerance

BVQBP6006

Good

BVQBP6009

No good

BODY PANEL REPAIR PROCEDURE

BP-7

REPLACING BODY PANEL

REMOVAL

1.

Body measurement
a)

Before removing, measure the damaged area
according to the dimensions supplied in Body
Dimension, section BD. If deformation is present,
use a frame straightener to adjust.

b)

When removing a panel, apply clamps to prevent
damage of each part, and support the lower end
of the frame to prevent deformation during the
procedure.

2.

Cut and welding point selection
Cutting, if necessary, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.

3.

Cutting rough area for replacement part
Cutting should be done according to the following steps
to make removal easy:
a)

Use care when cutting an area close to a pipe or
wiring harness.

b)

Cut an area leaving 30~50 mm of tolerance.

4.

Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.

BVQBP6011

Reinforcement

Reinforcement

Cut area

BVQBP6012

BVQBP6013

BFDBP6601K