5. Mold the related parts.
Fill any holes by MIG or gas welding, and even out with a
hammer and dolly.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
6. Set the new front pillar lower stiffener and repair part.
• Align the repair part with the top cut section, then
cut it with a handsaw.
NOTE: Cut the side sill joint with a handsaw leaving an
overlap of 30 mm (1.2 in).
• Remove the undercoat from both sides of the areas
to be spot welded with a sander to expose the steel
plate.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Clamp the new front pillar lower stiffener and repair
part.
• Check the body dimensions (see
section 6
).
• Temporarally install the door, and check the door
hinge mounting position.
• Remove the repair part and MIG weld the front pillar
lower stiffener.
7. Tack weld the clamped sections.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
8. Temporarily mount the door and front fender.
• Remove the vise-grips, then mount the door.
• Check the clearance and level differences of the
door and fender.
9. Perform main welding.
• Weld the front pillar and side sill outer joints with a
MIG welder.
• Make 20% to 30% more spot welds than there were
holes drilled.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Make 5 mm (0.2 in) holes in the MIG weld holes with
the repair part, and weld the lower stiffener, upper
stiffener and dashboard upper side member with a
MIG welder.
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