Hyundai Atos: Body Repair Manual - part 19

81

BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly)

5.

MIG plug weld all holes

6.

Clean MIG welds with a disc grinder.

NOTE
1.

Be careful not to grind welded portions too much.

2.

The internal parts will be stronger if the weld traces are
not ground.

7.

Before welding the cowl side upper outer panel, apply the two
part epoxy primer and anti-corrosion agent to the interior of the
fender apron panel.

PRO-0230

PRO-0070

PRO-0220

PRO-0270

82

BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly)

8.

Install the cowl side upper outer panel in place.

9.

MIG plug weld all holes.

10. Clean and prepare all welds, remove all residue.
11. Apply the two part epoxy primer to the interior of the each panel.

12. Apply an anti-corrosion agent as required

(Refer to the CORROSION PROTECTION).

13. Prepare the exterior surfaces for priming using wax and grease

remover.

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

17. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATION).

18. Reprime over the seam sealer to complete the repair.

19. After completing body repairs, carefully apply under coating to

the front sidemember and fender apron (Refer to the CORRO-
SION PROTECTION).

20. In order to improve corrosion resistance, if necessary, apply an

under body anti-corrosion agent to the panel which is repaired
or replaced (Refer to the CORROSION PROTECTION).

PRO-0270

PRO-0290

PRO-0260

PRO-0280

83

FRONT SIDE MEMBER (PARTIAL)

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

L/H

z

z

z

z

z MIG plug welding

MIG butt welding

z

z

z

z

z MIG plug welding

MIG butt welding

R/H

WELDLING POINTS

PRO-0301

PRO-0320

PRO-0300

PRO-0321

200mm

110mm

180mm

80mm

84

REMOVAL

NOTE
This procedure is to be used only for repair of minor damage
to the front side member and when it is impossible to straighten
the damaged side member. The following procedure illustrates
a repair for the front left side member.
The procedure may also be applied to the front right side-
member.

1.

Measure and mark the vertical cutlines on front side member
inner  tooling hole center.

2.

Drill out all the spotwelds to separate battery tray leg bracket from
front side member.

NOTE
1.

When spotwelded portions are not apparent, remove
paint with a rotary wire brush.

2.

In order to perform cutting and separation of spotwelded
points use a spot weld cutter which is larger than the
size of the nugget to make a hole only in the panels to
be replaced.

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

PRO-0301A

PRO-0360

PRO-0370

PRO-0300A