Hyundai Atos: Body Repair Manual - part 25

105

3.

Determine if the side sill outer reinforcement is damaged and
needs to be replaced. If replacing is necessary, mark out the
damaged portion of the side sill outer reinforcement.

        Cut at cutlines and remove the damaged portion.
4.

Prepare all surfaces to be welded.

INSTALLATION

1.

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

2.

Drill 8 mm holes in overlap areas on each end and upper flange
of new side sill outer reinforcement and clamp.

3.

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

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

4.

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

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

5.

Transcribe the side sill outer panel cutline to the new side sill,
adding 30 mm overlap to each end, cut and chamfer butt end to
improve weld surface.

6.

Drill 8 mm holes in overlap areas on each end and along upper
and lower flanges of the new side sill outer panel for MIG plug
welding.

PRO-1130

PRO-1140

PRO-1150

PRO-1160

50 mm

50 mm

106

7.

Fit and clamp the side sill in place.

8.

MIG plug weld all holes and MIG butt weld seams.

9.

Clean and prepare all welds, removing all residue.

10. Apply body filler to the side sill outer seams.
11. Apply the two-part epoxy primer to the interior of the side sill.

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

the side sill (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 anti-corrosion primer to the side sill outer panel to

complete the repair (Refer to the CORROSION PROTECTION).

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

PRO-1170

PRO-1180

PRO-1190

107

BODY PANEL REPAIR PROCEDURE - Rear side outer panel

REAR SIDE OUTER PANEL

WELDLING POINTS

PRO-1230

PRO-1200

!

!

!

!

!

A

$

$

$

$

$ MIG plug welding

MIG butt welding

xx MIG lap welding

%

B

PRO-1240

%

B

%

A

108

2.

Drill out all attaching spotwelds on the rear side outer panel,
including the seam around the door lip opening.

3.

Cut the rear side outer panel at cutlines and remove the rear side
outer panel as illustrated.

NOTE
When cutting the rear side outer panel, be careful not to cut
quarter inner panel.

REMOVAL

1.

Depending on the extent of damage, measure and mark cutlines
on the rear side outer panel as indicated in the illustration.

BODY PANEL REPAIR PROCEDURE - Rear side outer panel

PRO-1250

PRO-1290-

1

PRO-1270

150mm

PRO-1280

INSTALLATION

1.

Transcribe the cutline to the new rear side outer panel, adding
30mm for overlap at the old joint.

2.

Drill 8 mm holes in overlap areas and along upper and lower
flanges of the new rear side outer panel for MIG plug welding.