Hyundai H1: Body Repair Manual - part 24

98

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

QUARTER OUTER PANEL

LONG BODY (LH)

QSAQ2040

B

A

WELDING POINTS

QSAQ2020

QSAQ2030

 

 

 

 

 

B

 

 

 

 

 

A

,

Spot welding or MIG plug welding

MIG butt weldling

99

REMOVAL

1.

Depending on the extent of damage, measure and mark cutline
on the quarter outer panel 170 mm downward from the rear
window LH glass upper line as  illustration.

2.

Measure and mark cutline on the quarter outer panel 160 mm
downward from the quarter window LH glass upper line as
illustration.

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

3.

Measure and mark cutline on the quarter outer panel 150 mm
upward from the quarter window LH glass lower line as illustra-
tion.

4.

Drill out all spotwelds attaching the quarter outer panel to the
inner panel below cutlines.

QSAQ2050

QSAQ2060

QSAQ2070

QSAQ2080

Quarter outer panel

160 mm

150 mm

170 mm

100

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

QSAQ2090

5.

Cut quarter outer panel along cutlines to remove quarter outer
panel.

NOTE
1) Becareful not to cut quarter inner panel.

QSAQ2110

6.

Remove quarter outer panel.

7.

Prepare all surfaces to be welded.

QSAQ2120

QSAQ2100

2) When cutting "C"  outer pillar (Left side), be careful not
    to cut reinforcement panel as illustration.

101

INSTALLATION

1.

Measure and mark guide lines 30 mm upward and downward
from "B" pillar outer panel, "C" pillar outer panel and "D" pillar
outer panel cutlines.

2.

Drill 8 mm holes where the insertion panel to be installed.

3.

Make an insertion panel with 60 mm width from unused portion
of the panel.

4.

Fit and clamp the insertion panel in place for welding.

5.

MIG plug weld the insertion panel.

6.

Transcribe the cutline to the new quarter outer panel, cut to
length and chamfer butt end to improve weld surface.

7.

Drill 8 mm holes in production locations along outer panel
flanges and insertion panel for attachment to other panels.

BODY PANEL REPAIR PROCEDURE - Quarter outer panel

QSAQ2050

QSAQ2060

QSAQ2070

QSAQ2160

Insertion
panel

Insertion panel

60 mm

60 mm

60 mm

Insertion
panel