Mitsubishi Evolution X. Manual - part 46

ALUMINUM PANEL

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WELDED PANEL REPLACEMENT

3-54

CAUTION

To minimize distortion and meltdown, divide a welding 
area into several short segments, and weld one segment at 
a time.
2. Welding: Use an aluminum dedicated welding machine or a 

shared welding machine for aluminum and steel sheet for 
the operation.
Wire diameter: 0.8 or 1.0 mm (0.031 or 0.039 inch)

(1) Degrease the welding area by white gasoline or the like.
(2) Remove the oxide coat from the welding area, including 

its back, with a stainless steel wire brush just before 
welding. Welding shall be started as soon as the oxide 
coat is removed.

CAUTION

Do not over-grind the base of the panel.
3. Refinish the welding area by a #100-grit disk sander, and 

then check for any faulty welding by the visible dye 
penetrate testing.

4. Check for distortion: Grind the surface with #80 to #120-grit 

sandpaper and then check for distortion.

CAUTION

• The heating temperature should be approximately 

250

°C (482°F).

• Pay particular attention to heating, because it is melted 

without discolouration by heat.

• Cover the vicinity of the area to be heated with a wet 

rag or the like to prevent temperature rise and influence 
of heat (distortion).

• Do not use a draw hammer for steel sheets because it 

may cause the panel crack.

5. Remove distortion by the draw correction procedure with a 

flattening hammer and a burner.

AB202118 AB

AB202117AB

AB202113

AB

ALUMINUM PANEL

TSB Revision

WELDED PANEL REPLACEMENT

3-55

CAUTION

Remove any spark spot or carbon residue on the surface 
by a stainless steel wire brush, because they will cause 
improper painting in the following process.

6. Finishing: Finish it with a #100 to #120-grit disc sander.

Other welding

.

TIG WELDING

1. This welding is conducted by the same arc welding method 

as for MIG welding, however, it uses a welding rod instead 
of electrode wire.
Wire diameter: 1.6 mm (0.063 inch).

CAUTION

• Be careful to avoid excessive stretch of or damage to 

the panel.

• Minimize the gap of the butt joint.

.

GAS WELDING (OXIDE - ACETYLENE)

If gas welding is allowed, the welding can be conducted using a 
welding rod and flux (oxide coat remover). However, before the 
welding work, do sufficient practice to avoid distortion by weld-
ing heat or poor welding.
Wire diameter: 1.6 mm (0.063 inch).
1. Heat the welding rod and bond the flux to it.

AB302174

AB

AB202109

AC

AB202108

AB

AB302175

AB

ALUMINUM PANEL

TSB Revision

WELDED PANEL REPLACEMENT

3-56

CAUTION

Keep the welding surface as horizontal as possible, 
because the melted welding rod flows readily.
2. While melting the flux with the burner to remove the oxide 

coat, conduct the welding.

3. Remove the flux residue from the panel with a stainless 

steel wire brush.

Finish with putty

.

1. Grind the putty-applied area with a #150 to #180-grit 

double-action sander.

2. Degrease and clean the putty-applied area.
3. Apply 2-liquid type epoxy primer or a pretreatment agent for 

aluminum.

4. Grind with a #180-grit double-action sander for cutting 

action.

5. Degrease and clean the putty-applied area.
6. Apply putty for metal sheets, and dry it naturally.

CAUTION

Do not dry it forcibly at 60

°C (140°F) or higher.

7. Grind with a #180-grit sander.

AB302176

AB

AB202114

AB

AB302177

AB

ALUMINUM PANEL

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WELDED PANEL REPLACEMENT

3-57

ALUMINUM PANEL PAINT

M4030000800163

.

Painting in production line

Same as painting for normal steel sheets.

.

Precautions upon sheet metal processing

CAUTION

• Avoid hasty grinding and minimize grinding heat.
• Do not dry it forcibly at higher than 60°C (140°F).

1. Peel-off of paint film
2. Cleaning and degreasing

CAUTION

Apply 2-liquid type epoxy primer or a pretreatment agent 
for aluminum to the aluminum base surface.
3. Application of wash primer
4. Drying <60

°C (140°F) or lower>

5. Application of primer surfacer
6. Drying <60

°C (140°F) or lower>

7. Grinding
8. Cleaning and degreasing
9. Finish coating
10.Drying <60

°C (140°F) or lower>

NOTE: 

.

•

Refer to paint manufacturers' paint specifications for details.

•

The procedure is almost the same as the repair painting 
procedure of anti-corrosion steel panel.