1. Using the jig saw, follow the cutting lines in the diagram.2. Use the chisel to cut along the lines illustrated in the diagram.- Use a rotary brush to remove the paint and gain access to the spot welds.3. Use the chamfering machine to remove the spot welds shown in the diagram.- Use the drill to chamfer the spot welds that are not accessible to the chamfering machine.- Use a hammer and chisel to remove the previously chamfered spot welds.- Remove the offcuts from the vehicle.
- Straighten the edges of the vehicle using a hammer and dolly block.- Remove the spot weld residues using a disc grinder.- Use a rotary brush to clean the previously treated areas.1. Apply electro-galvanizing paint.
Refitting
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Removing
)
1. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the replacement part using a rotary brush.- Position the part and check the part coupling carefully. Trim if necessary.2. Drill out the part at the indicated points.- Apply electro-weldable paint to the edges involved.
1. Position the replacement part correctly on the vehicle and secure it using self-locking clamps.- Check the alignment and the surrounding gaps.2. Use a spot welder to weld the areas shown in the diagram.3. Apply a few tack welds in the upper area. Weld permanently when the roof is secured.4. Use a MIG welder to fill weld the openings made previously.5. Use a MIG welder to seam weld in the join areas.
- Correct any distortions to the panel using a mallet and dolly block.1. Use a disc grinder to level the welds.- Use a rotary brush to clean the previously welded areas.
1. Apply anti-oxidant protection to the areas involved in the welding.- Seal the join lines between the replacement part and the vehicle.
Removing
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Refitting
)
Op. 7210E56 R.R. TAILGATE Op. 7210E28 R.R. ROOF PANEL Op. 7210E36 R.R. FRONT SIDE DOOR Op. 7210E38 R.R. REAR SIDE DOOR - Ensure that the components connected are not distorted by checking the bodyshell alignment measurements with suitable equipment (gauges, templates or jigs).- Straighten the body as necessary.
