Hyundai Atos: Body Repair Manual - part 23

97

BODY PANEL REPAIR PROCEDURE - Front side outer panel

INSTALLATION

1. In order to install center inner pillar drill out all spotwelds attaching

the roof side inner rail to center inner pillar to separate them.

2. Transcribe the front side outer panel cutlines to the new front side

outer panel, adding 30mm overlap at center inner pillar ends.

3. Cut and chamfer butt end to improve weld surface.
4. Drill 8mm holes in overlap area and along outer panel flanges.

PRO-0850

PRO-0880

PRO-0840

PRO-0860

PRO-0870

30 mm

5. MIG butt weld all seams in center inner pillar and side sill outer

reinforcement and front side outer panel as show in the illustra-
tion.

98

BODY PANEL REPAIR PROCEDURE - Front side outer panel

6.

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

7.

Drill 8mm holes in overlap areas on each end of new side sill
outer reinforcement and clamp, the new side sill outer reinforce-
ment in place.

8.

MIG plug weld all holes and MIG butt weld seams.

NOTE
The reinforcement will be stronger if the weld traces are not
ground.

9.

Temporarily install new front side outer panel in place.

10. Screw center pillar in place.
11. Measure and each measurement point (Refer to the BODY

DIMENSIONS) and correct the installation position.

12. Check the fit of the front and rear doors.

13. Reinstall front side outer panel and screw in place.
14. MIG plug weld all holes and MIG butt weld all seams.
15. Clean and prepare all welds, and remove all residue.
16. Apply body filler to the front side outer panel seam. Sand and

finish.

17. Apply the two-part epoxy primer to the interior of the center inner

pillar.

PRO-0890

PRO-0900

PRO-0910

PRO-0920

99

BODY PANEL REPAIR PROCEDURE - Front side outer panel

18. Apply an anti-corrosion agent to the welded parts and interior of

the center inner pillar (Refer to the CORROSION PROTEC-
TION).

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

remover.

20. Apply metal conditioner and water rinse.
21. Apply conversion coating  and water rinse.

PRO-0940

PRO-0930

22. Apply the two-part epoxy primer.
23. Apply the correct seam sealer to all joints carefully (Refer to the

BODY SEALING LOCATIONS).

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

100

BODY PANEL REPAIR PROCEDURE - Side sill outer panel (Assembly)

SIDE SILL OUTER PANEL (ASSEMBLY)

REMOVAL

1.

Measure and mark vertical cutline from the front side outer panel
and rear side outer panel connecting portion.

2.

At the front side outer panel, measure and mark horizontal
cutlines from the door hinge mounting hole on the front side outer
panel as shown in the illustration.

WELDLING POINTS

PRO-0970

PRO-0950

PRO-0960

$

$

$

$

$ MIG plug welding

MIG butt welding

xx MIG lap welding