Hyundai Atos: Body Repair Manual - part 21

89

BODY PANEL REPAIR PROCEDURE - Front side outer panel

5.

Drill out all welds attaching the front side outer panel to dash and
cowl top outer, cowl inner lower panels.

6.

Remove spotwelds and lap welds attaching cowl crossmember
bar mounting upper bracket to remove front pillar.

7.

Before cutting front side outer panel, be sure to support roof
panel.

8.

Cut the front side outer panel through each cutline, taking care
not to damage the other panel as illustrated.

9.

Before cutting the side sill outer panel, make a rough cut the side
sill outer panel only.

NOTE
When cutting the front side sill outer panel, be careful not
to cut side sill outer reinforcement.

PRO-0540

PRO-0550

PRO-0560

PRO-0530

Front side outer
panel

Front inner upper
pillar

90

BODY PANEL REPAIR PROCEDURE - Front side outer panel

10. Cut the side sill outer reinforcement as shown in the illustration.
11. Cut the side sill outer reinforcement vertical cutline and remove

the front side outer panel.

12. Straighten all flanges as necessary, prepare all surfaces to be

welded.

INSTALLATION

1.

Transcribe the cutline to the new front inner upper pillar , cut to
length and chamfer butt end to improve weld surface.

2.

Transcribe the cutline to the new side sill outer reinforcement
and new front side outer panel, adding 30mm overlap to end and
cut to length.

3.

Drill 8mm holes along outer panel flanges in production location
for attachment to other panels.

PRO-0580

PRO-0590

PRO-0570

PRO-0600

30mm

91

BODY PANEL REPAIR PROCEDURE - Front side outer panel

4.

Transcribe the cutline to the new side sill outer reinforcement,
adding 30mm overlap to end and cut to length.

5.

Drill 8mm holes in the side sill outer reinforcement for MIG plug
welding.

6.

Fit and clamp the new side sill outer reinforcement in place for
welding.

7.

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

8.

Temporarily install front inner upper pillar and front side outer
panel in place.

9.

Measure and each measurement point (Refer to the  BODY
DIMENSIONS) and correct the installation position.

10. If necessary, make temporary welds, and then check to confirm

that the closing and fit for windshield glass, door and fender are
correct.

11. MIG butt weld front side outer panel and front side outer panel

seams.

12. Reattach the cut away front side outer panel section, then MIG

butt weld.

13. MIG  plug weld all holes and MIG butt weld all seams, in the front

side outer panel.

14. Clean and prepare all welds, remove all residue.
15. Apply body filler to joints and sand as needed.
16. Apply the two-part epoxy primer to the interior of the front side

outer panel.

PRO-0620

PRO-0630

PRO-0610

PRO-0640

92

BODY PANEL REPAIR PROCEDURE - Front side outer panel

17. Clean all 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.

18. Before welding the front inner lower pillar panel, apply the two

part epoxy primer and anti-corrosion agent to the interior of the
fender apron panel.

19. Install the front inner lower pillar panel in place.
20. MIG plug weld all holes.
21. Clean and prepare all welds, remove all residue.

22. Apply an anti-corrosion agent to the welded parts and inside

of front inner upper pillar (Refer to the CORROSION PRO-
TECTION).

23. Prepare exterior surfaces for priming, using wax and grease

remover.

24. Apply metal conditioner and water rinse.
25. Apply conversion coating and water rinse.

PRO-0460

PRO-0660

PRO-0670

PRO-0690

PRO-0680