Mitsubishi Lancer Evolution 8 MR. Manual - part 10

3-2

CHANGING WELDED PANELS – ROOF

Symbol

Operation details

● ● ● ●

Spot welding

■ ■ ▲ ▲

MIG plug welding ( 

■

: two layers  

▲

: three layers)

+ + + +

MIG spot welding

✝✝✝✝✝✝✝✝

MIG arc welding (continuous)

★ ★ ★ ★

Rivet

Areas where rust inhibitor is applied. (Applied using
holes in butt welded locations)

Front pillar
upper support

Centre pillar
upper support

Rear pillar upper
support

Note

❉

: these welding points are done by manufacturer (not necessary during repairs).

:

black shading indicates areas where structural adhesive is applied.

Adhesive Type

Product name

Epoxy structural adhesive Sumitomo 3M Auto Mix Panel Bond 8115

SERVICE JOINTS

3-3

CHANGING WELDED PANELS – ROOF

(Front  pillar upper support

(Rear pillar upper support

removed condition)

removed condition)

IMPORTANT POINTS TO OBSERVE  WHEN DOING THE
WORK

REMOVAL

1. When removing the roof, use a support to prevent the side

panels opening out or leaning in.

2. To cut weld the front or rear roof rail, remove the front pillar

upper support and rear pillar upper support.

3. Using a drill (

∅

5mm), make a hole in through the centre of the

rivet, crack it, and remove. Normally, self-piercing rivets are
used, but blind rivets may also be used.
For areas where there is adhesive, use a cold chisel or similar
tool to free and remove the roof.

Self-piercing rivet

Blind rivet

Drill

Rivet

Roof panel

3-4

CHANGING WELDED PANELS – ROOF

Fitting

1. Temporarily set the new roof to the body, and drill holes for

rivets with drill (

∅

5mm).

2. Remove the roof, smooth off any burring around the holes,

then clean the body.

3. Apply structural adhesive to the body side, then fit the roof.

4. Using the appropriate tool, set the rivets as follows:

Rivets: POP rivet SD-62-HR
(1) Insert the rivet into the hole in the base material (roof).
(2) Insert the appropriate tool into Part A of the rivet.
(3) Using the appropriate tool, use the tool handle to press the
rivet flange surface down.
(4) Secure the rivet, snapping at the thin part of A.

Note

In places where setting rivets so that flange makes good
contact is difficult, it is OK to set from inside the vehicle.

Reference:
Appropriate tool (use rivet 

∅

4.8mm)

Lobster Tools Ltd
Hand riveter: HR-003B

5. When adhesive is dry, remove any excess adhesive then, to

prevent water ingress, apply body sealant to cover entire rivet
area and roof edge.

: black shading indicates body sealant

Product name: Sun Star Penguin Seal 353 (white)

Adhesive   Type

Product name

Epoxy structural
adhesive

Sumitomo 3M Auto Mix
Panel Bond 8115

appropriate tool

part A   

appropriate

tool

flange

rivet 

Roof panel

Body sealant

Rivet

 

3-5

CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS

ALUMINIUM ALLOY PANELS

Repairing Aluminium Alloy Panels

Precautions when working on sheet metal

1. The main differences to working with sheet steel. (Assuming an ordinary body shop)

Operation

Aluminium alloy panel

Sheet steel

Hammering

Wood or plastic hammer

Sheet steel hammer

Washer welding Not possible

Possible

Gas welding

Workability is poor but possible

Possible

Spot welding

Not possible

Possible

MIG welding

Possible with welder using argon gas and equipment for
aluminium welding

Possible with CO

2

gas and normal welding

equipment

2. At low temperatures, if subjected to a major impact, strength will deteriorate and it will crack.
3. Coefficient of elasticity is high, so spring-back (force acting to make material regain original form) is high.
4. Rate of heat transmission is high, and this can cause local thermal expansion.
5. If overheated, it becomes brittle, and strength deteriorates. If heated further, it will melt without discolouration.

(Heat treatment temperature: approx. 250˚C)

Material

Welding temperature

Aluminium

475˚C~660˚C (varies depending on alloy composition)

Sheet steel

1500˚C~2500˚C

6. Material is soft, so be careful when selecting polish to use.

Also, since polishing powder is light and easily airborne, wear dust mask and goggles.

7. If strong pressure is used when using a disk sander on the alloy, the friction could cause the aluminium alloy to peel off,

and cause clogging.

8. Disk sanders that become clogged will cause deep scratching on aluminium alloy panels, so replace promptly.
9. Do not use general tools or sanders for sanding sheet steel.

(steel fragments or dust will remain on the sander, causing electro-corrosion with other metal)

10. With MIG welding, shield the local area. Sparks, often difficult to see, can be generated and dispersed over a wide area.

Repairing unevenness

This is basically the same as for sheet steel. However, bear in mind
aluminium alloy characteristics when carrying out this work.
1. Repairing sheet metal

(1) Heat with a torch

Note
a. Heat to the point where heat can be felt on the rear side
of panel with hand wearing a glove.
b. Keep torch moving so as not to overheat one area.