Mitsubishi Outlander XL. Manual - part 26

ZB6001100000

4.

Sanding: Grind the surface with a disk sander or a double-
action sander.

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Disk sander: #100 to #120

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Double-action sander: #150 to #180

Aluminum plates are softer than steel sheets, therefore
select an appropriate abrasive to prevent the surface from
deeply  scratched.  The  heating  temperature  should  be
approximately 250°C (482°F).

Correction of cuts and cracks

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If cuts, cracks, or holes occur in a steel sheet panel, MIG welding
with CO2is used for repair. However, for an aluminum panel, use
MIG or TIG welding with argon gas (inert gas) as shielding gas
for repair.

DEGREE OF DISTORTION CAUSED BY WELDING
Gas  welding  (a  large  amount  of  distortion)  TIG  welding  MIG
welding (a small amount of welding). This manual explains the
operation  procedure  of  MIG  welding  which  causes  a  small
amount of distortion by welding heat.

Operation procedure of MIG welding

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0000

｠

Be careful to avoid excessive stretch of or damage to the
panel.

｠

Minimize the gap of the butt joint.

1.

Correct the damaged area by hammering lightly while heating
it. If any area is stretched by hammering, grind it off with a
pneumatic saw.

WELDED PANEL REPLACEMENT

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ALUMINUM PANEL

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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 inches)

(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.

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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.

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4.

Check for distortion: Grind the surface with #80 to #120-grit
sandpaper and then check for distortion.

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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.

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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.

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WELDED PANEL REPLACEMENT

ALUMINUM PANEL

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Other welding

TIG WELDING

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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 inches).

｠

Be careful to avoid excessive stretch of or damage to
the panel.

｠

Minimize the gap of the butt joint.

GAS WELDING (OXIDE - ACETYLENE)

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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 welding
heat or poor welding.
Wire diameter: 1.6 mm (0.063 inches).

1.

Heat the welding rod and bond the flux to it.

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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.

WELDED PANEL REPLACEMENT

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ALUMINUM PANEL

Finish with putty

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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.

Do not dry it forcibly at 60°C (140°F) or higher.

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7.

Grind with a 180-grit sander.

ALUMINUM PANEL PAINT

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Painting in production line
Same as painting for normal steel sheets.

Precautions upon sheet metal processing

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Avoid hasty grinding and minimize grinding heat.

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Do not dry it forcibly at higher than 60°C (140°F).

1.

Peel-off of paint film

2.

Cleaning and degreasing

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.

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WELDED PANEL REPLACEMENT

ALUMINUM PANEL