Hyundai Atos: Body Repair Manual - part 20

85

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

3.

Cut through the front side member inner and outer at cutlines.

NOTE
Take care not to cut through front side member inner
reinforcement.

4.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the front side member inner and outer cutline to the
new front side member, cut to length and chamfer butt end to
improve weld surface.

2.

Drill 8mm holes in new front side member for MIG plug welding.

3.

Fit and clamp the front side member inner and outer in place.

4.

MIG plug weld all holes and MIG butt weld all seams.

5.

Measure each measurement point (Refer to the BODY DIMEN-
SIONS) and correct the installation position.

PRO-0390

PRO-0400

PRO-0410

PRO-0380

86

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

6.

Fit and clamp the radiator support panel in place.

7.

MIG plug weld all holes.

8.

Clean and prepare all welds, removing all residue.

9.

Apply the two-part epoxy primer to the interior of the front side
member.

10. Apply an anti-corrosion agent as required.

(Refer to the CORROSION PROTECTION).

11. Prepare the exterior surfaces for priming, using wax and grease

remover.

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

PRO-0420

PRO-0430

PRO-0440

15. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

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

87

FRONT SIDE OUTER PANEL

BODY PANEL REPAIR PROCEDURE - Front side outer panel

z

z

z

z

z MIG plug welding

MIG butt welding

xx MIG lap welding

WELDLING POINTS

Ô

Ô

Ô

Ô

Ô

A

Ô

Ô

Ô

Ô

Ô

B

PRO-0450

PRO-0490

PRO-0470

Ô

Ô

Ô

Ô

Ô

D

PRO-0480

Í Í Í Í Í

Ó

Ó

Ó

Ó

Ó

C

ÎÎÎÎÎ

A

Ô

Ô

Ô

Ô

Ô

C

PRO-0460

ΠΠΠΠÎ

D

B

88

BODY PANEL REPAIR PROCEDURE - Front side outer panel

REMOVAL

1.

Measure and mark the each cutline on the front side outer panel
and front inner upper pillar frame  from the wiring fixing hole as
indicated in the illustration.

2.

Measure and mark the cutline on front side sill inner panel as
shown in the illustration.

3.

Depending on the extent of damaged area, it may be possible to
determine the cutting range within indicated in the illustration.

4.

To remove the front  side outer panel, grind away and drill out all
welds on the front inner lower pillar and front side outer panel as
shown in the illustration.

PRO-0510

PRO-0520

PRO-0500

50mm

PRO-0511

150mm

120mm