Mitsubishi Evolution X. Manual - part 5

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-17

CAUTION

Perform the operations carefully so that the cut ends fit 
together properly.
11.Cutting of new parts by using a measurement marking

If overlap cutting is not possible in a place where butt 
welding is to be done, make a measurement marking on the 
new part at the exact same measurement which was used 
for the cutting of the body panel, and then cut the new part 
by using this measurement marking.

• Two-layer construction

When cutting a front pillar or center pillar which has a 
two-layer construction but no reinforcement, make the cut-
ting of the inner panel and that of the outer panel approxi-
mately 50 mm (1.97 inches) apart in order to obtain 
maximum strength.

• Three-layer construction

When cutting a front pillar or center pillar which has a 
three-layer (including a reinforcement) construction (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the 
reinforcement. If the inner panel is an assembly replace-
ment part, cut it at two places in order to provide ample 
working space for the butt welding of the reinforcement.

12.Application of spot sealer to spot-welded points

Apply an electro-conductive spot sealer to the connecting 
surfaces of both the new parts and the vehicle body in order 
to provide corrosion protection.

AB200062 AD

Outer panel

Approx. 50 mm

(1.97in)

Inner panel

Twolayer construction

AB200063AD

Inner panel

Inner panel
cut line

Inner panel cut line

Outer panel
and reinforce-
ment cut line

Three-layer construction

AB200064

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-18

CAUTION

During temporary mounting, it is extremely important to 
obtain accurate measurements for each component. The 
mounting positions for the front and rear suspensions are 
especially crucial with regard to safety; therefore, it is nec-
essary that all work concerning these areas be done care-
fully and correctly.
13.Temporary mounting of new parts

(1) In order to bring the new parts into the proper mounting 

position, measure each part carefully and make any 
corrections necessary in order to obtain agreement with 
the measurements.

(2) In addition, make temporary welds, and then check to 

confirm that the closing and fit of the doors, fenders, etc., 
are correct.
For parts which should be symmetrical to the body 
center, measure the distances from the body center point 
to both the left part and the right part, and confirm that the 
distances are the same.

CAUTION

Weld completely so that there are no pinholes.
14.Butt welding

For burr welding, make a 10 

− 15 mm (0.39 − 0.59 inch) MIG 

spot weld, and then, in order to prevent warping which might 
be caused by the welding heat, complete the welding by 
making welds of the specified width at alternate positions.

AB200065

AB200066

AB200067

AB200068

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-19

15.Spot welding

When doing spot welding, it is not only important to correctly 
position the electrode tips, but also to hold the two panels 
securely together with vise-grip pliers or some other type of 
clamps, being sure that they are in perfect contact with each 
other.

• Be sure that the force applied by the arm is sufficient.

• Use a test piece to check the secondary current and the 

current application time of the spot welder, and adjust the 
values as appropriate.

16.Plug welding

If spot welds cannot be made, make holes for plug welding 
in the new parts, and then MIG weld. Because the quality of 
the fusion varies according to the size of the holes, they 
should be about 5 

− 6 mm (0.2 − 0.24 inch) in diameter. In 

addition, be sure the two surfaces are in complete contact 
with each other by using vise-grip pliers to securely hold 
them.
NOTE: Depending on the working conditions, it might also 
be necessary to make holes in the panel remaining on the 
body

17.Hemming (Adhesion type)

(1) Apply an adhesive to the area to be hemmed of the door 

outer panel.

(2) For the area to be hemmed of the door outer panel, apply 

an adhesive and smooth the panel with a hammer and a 
dolly. Then, hem the panel with a hemming tool.

AB200070

AB200070

AB500010

AB401282

A

Section

AD

AB500010

AB401282

A

A – A

AB200072AD

Hemming tool

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-20

18.Hemming (Welded type)

(1) For the area to be hemmed of the door outer panel, etc., 

smooth the panel with a hammer and a dolly, and hem it 
with a hemming tool.

(2) After completing the hemming work, make MIG spot 

welds at 50 

− 60 mm (1.97 − 2.36 inches) intervals on the 

inside.

CAUTION

Be sure not to grind the panel down too much. Before 
welding the outer panel, be sure to apply an anticorrosion 
agent.
19.Finishing work for butt welding and plug welding

Do the finishing work to smooth the protruding weld traces. 
However, the butt joints of reinforcements and other internal 
parts will be stronger if the weld traces are not finished.

20.Application of body sealant

Apply a coating of sealant carefully, without breaks, as 
described in the section (of the manual corresponding to 
that model).
NOTE: After application has been made to any external sur-
faces, perform smooth-finishing work.

AB200072AD

Hemming tool

AB200073

AB200074

AB200076