Hyundai Atos: Body Repair Manual - part 24

101

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

3.

Cut the side sill outer panel along cutlines. Be careful not to cut
mating flanges.

4.

Drill out all spotwelds, attaching the side sill outer panel to side
outer reinforcement.

5.

Remove the side sill outer panel.

6.

Determine if the side sill outer reinforcement is damaged and
needs to be replaced, measure cutline on reinforcement as
shown in the illustration.

7.

Cut side outer reinforcement along the cutline.

8.

Drill out spotwelds attaching the side sill outer to the body and
remove side sill outer reinforcement.

9.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe cutline dimension to side sill outer panel, adding
30mm overlap to rear end and cut to length.

2.

Drill 8mm holes in overlap area on rear end and along front
flange.

3.

Fit and clamp the side outer reinforcement in place.

4.

MIG  plug  weld all holes and MIG butt weld seams.

5.

Before welding the side sill outer panel, apply the two-part epoxy
primer and anti-corrosion agent to the welded parts.

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

PRO-1000

PRO-1010

PRO-1030

PRO-1040

102

B

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

7.

Crimp flanges on the remaining portion of the side sill outer panel
at all joint for overlap.

8.

Fit and clamp the side sill outer panel in place.

9.

MIG plug weld all holes and MIG butt weld seams.

10. Clean and prepare all welds and remove all residue.
11. Apply body filler to the side sill outer seams.
12. Apply the two-part epoxy primer to the interior of the side sill.

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

side sill (Refer to the CORROSION PROTECTION).

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

remover.

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

6.

Using service panel for replacement of side sill outer panel, drill
8mm holes in overlap areas and along upper and lower flanges.

18. Apply the correct seam sealer to all joints (Refer to the BODY

SEALING LOCATIONS).

19. Reprime over the seam sealer.

PRO-1050

PRO-1060

PRO-0930

PRO-1080

103

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

20. Apply the anti-corrosion primer to the side sill outer panel to

complete the repair (Refer to the CORROSION PROTECTION).

PRO-1090

104

SIDE SILL OUTER PANEL (PARTIAL)

REMOVAL

1.

Depending on the extent of damage, mark out the damaged
portion of the side sill.

2.

Drill out the spotwelds in upper and lower flanges of side sill
between cutlines to remove side sill outer panel and cut the
damaged portion of the side sill at the cutlines.

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

WELDLING POINTS

PRO-1100

PRO-1110

PRO-1120

50 mm

50 mm

$

$

$

$

$ MIG plug welding

MIG butt welding

xx MIG lap welding