Hyundai Getz: Body Repair Manual - part 25

105

3.

Determine if the side outer reinforcement is damaged and needs
to be replaced. If replacing is necessary, mark out the damaged
portion of the side outer reinforcement. Cut at cutlines and
remove the damaged portion.

4.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the cutline to the new front side outer reinforcement,
adding 30 mm overlap to each end and cut to length.

2.

Drill 8 mm holes in overlap areas on each end and upper flange of
new side outer reinforcement and clamp the new  side outer
reinforcement in place.

3.

MIG plug weld all holes and MIG butt weld all seams.

NOTE
The reinforcement will be stronger if the weld traces are not
ground.

4.

Before welding the side sill outer panel, apply the two part epoxy
primer and anti-corrosion agent to the welded parts.

BODY PANEL REPAIR PROCEDURE - Side sill (partial)

5.

Transcribe the side sill outer panel cutline to the new side sill,
adding 30 mm overlap to each end, cut and chamfer butt end to
improve weld surface.

6.

Drill 8 mm holes in overlap areas on each end and along upper and
lower flanges of the new side sill outer panel for MIG plug welding.

PRO-1130

PRO-1140

PRO-1150

PRO-1160

106

7.

Fit and clamp the side sill in place.

8.

MIG plug weld all holes and MIG butt weld seams.

9.

Clean and prepare all welds, remove all residue.

10. Apply body filler to the side sill outer seams.
11. Apply the two-part epoxy primer to the interior of the side sill.

12. Apply an anti-corrosion agent to the welded parts and interior of

the side sill (Refer to the CORROSION PROTECTION).

13. Prepare the exterior surfaces for priming, using wax and grease

remover.

14. Apply metal conditioner and water rinse.
15. Apply conversion coating and water rinse.
16. Apply the two-part epoxy primer.

17. Apply the anti-corrosion primer to the side sill outer panel to

complete the repair (Refer to the CORROSION PROTECTION).

BODY PANEL REPAIR PROCEDURE - Side sill (partial)

PRO-1170

PRO-1180

PRO-1190

107

BODY PANEL REPAIR PROCEDURE - Quarter panel

QUARTER PANEL

z

z

z

z

z MIG plug welding

MIG butt welding

WELDLING POINTS

PRO-1220

Ô

A

PRO-1200

PRO-1201

Ô

B

Ô

C

PRO-1202

Í

Í

C

A

B

Í

108

2.

Drill out all attaching spotwelds on the quarter outer panel,
including the seam around the door lip opening.

3.

Cut the quarter outer panel at cutlines and remove the quarter
outer panel as illustration.

NOTE
When cutting the quarter outer panel, be careful not to cut
quarter inner panel.

4.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the cutline to the new quarter outer panel, adding 30
mm for overlap at the old joint.

2.

Drill 8 mm holes in overlap areas and along upper and lower
flanges of the new quarter outer panel for MIG plug welding.

3.

Fit and clamp the quarter outer panel in place.

4.

MIG plug weld all holes and MIG butt weld seams. At the wheel
well the edge must be crimped over the wheel housing.
This joint may be welded after crimping or applying a bead of
adhesive which may be applied to the joint before or after
crimping.

5.

Clean and prepare all welds, remove all residue.

REMOVAL

1.

Depending on the extent of damage, measure and mark cutlines
on the quarter outer panel as indicated in the illustration.

BODY PANEL REPAIR PROCEDURE - Quarter panel

PRO-1250

PRO-1260

PRO-1250

PRO-1260

PRO-1300

PRO-1270

30mm

420mm

30mm

200mm

480mm