Chevrolet Silverado / GMC Sierra. Manual - part 1279

Fig. 38: Drilling Plug Weld Holes Along Sectioning Cut 
Courtesy of GENERAL MOTORS CORP. 

3. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the remaining original part. Locate these 

holes approximately 25 mm (1 in) from the edge and spaced 40 mm (1 1/2 in) apart. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

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Fig. 39: Drilling Plug Weld Holes In Rocker Panel Section 
Courtesy of GENERAL MOTORS CORP. 

4. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the 

original panel and along the sectioning cut. 

IMPORTANT: If the location of the original plug weld holes can not be determined, or if 

structural weld-thru adhesive was present, space the plug weld holes 
every 40 mm (1 1/2 in) apart.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

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Fig. 40: Fitting & Plug Weld Backing Plate To Vehicle 
Courtesy of GENERAL MOTORS CORP. 

5. Prepare all attachment surfaces as necessary.  

6. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion 

Treatment and Repair .  

7. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

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Fig. 41: Installing & Plug Weld Rocker Panel Section 
Courtesy of GENERAL MOTORS CORP. 

8. Position the body side to the vehicle using 3-dimensional measuring equipment. Clamp in place. 

9. Clean and prepare all welded surfaces.  

10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion 

Treatment and Repair .  

11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .  

12. Install all related panels and components.  

13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection 

(w/Single Battery) or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery)

IMPORTANT: To create a solid weld with minimum heat distortion, make 25 mm (1 in) 

stitch welds along the seam with 25 mm (1 in) gaps between them. 
Complete the stitch weld.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

Page 45 

© 2005 Mitchell Repair Information Company, LLC.