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4. Mold the inner panel and related parts. • Fill and holes drilled by MIG or gas welding. To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes. • Level and finish burrs, etc. with a disc sander. To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding. • Remove the undercoat from both sides of the weld flange with a sander to expose the steel plate. 6. Set the repair part. • Install the outer panel and clamp it with vise-grips. NOTE: Apply the spot sealer to the welding surface when spot welding. 5. Cut the replacement part. • Cut so that the repair part overlaps the side sill by 30 mm (1.2 in). • Apply body paint to the back of the repair part. • See Paint Repair section. • Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening the paint container. • Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. • Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes. • Check the body dimensions (see ). 7. Tack weld the repair part. To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes. Temporarily spot weld the panel at the clamped posi- tions. 8. Remove the vise-grips and check the alignment of the door and trunk lid. NOTE: • Check for flushness of the front fender, door, and the rear fender and make sure the body lines flow smoothly. • Check the rear window openings. (cont'd) Main Menu Table of Contents |