Land Rover Panel Repairs Procedures Rover Manual

							PANEL REPAIRS
PROCEDURES3REVISED: PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic
panel removal and replacement method. This
standard method might vary slightly from one vehicle
to another. The main criterion in removal and
replacement of body panels is that Rovers original
standard is maintained as far as possible.
Remove Panel
1.Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheel arch areas it may be
necessary to soften underbody coating
using a hot air gun, prior to exposing spot
welds.
2.Cut out welds using a cobalt drill.
3.Alternatively use a clamp-type spot weld
remover. 
						

							PANEL REPAIRS
4
PROCEDURESREVISED:
4.Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.Prepare Old Surfaces
1.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat.
CAUTION: CARE MUST BE TAKEN TO
AVOID EXCESSIVE HEAT BUILD-UP
WHEN USING THIS EQUIPMENT.
2.As an alternative a disc sander may be used.
Straighten existing panel joint edges using
shaping block and hammer. 
						

							PANEL REPAIRS
PROCEDURES5REVISED: Prepare New Surfaces
1.Mark out bulk of new panel and trim to size,
leaving approximately 50mm overlap with
existing panel. Offer up new panel/section,
align with associated panels (e.g. new rear
quarter aligned with door and tailgate). Clamp
into position.
2.Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.
3.Prepare new panel joint edges for welding by
sanding to a bright finish. This must include
inner as well as outer faces.
4.Apply suitable weld-through primer to panel
joint surfaces to be welded, using brush or
aerosol can. 
						

							PANEL REPAIRS
6
PROCEDURESREVISED:
5.Apply adhesive sealant to panel joint surfaces.
See INFORMATION, Sealing and corrosion
protection.
Offer Up and Align
Offer up new panel and align with associated
panels. Clamp into position using using welding
clamps or Mole grips. Where a joggle or brace joint
is being adopted, make a set in the original panel
joint edge or insert a brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.Welding
1.Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
CAUTION: Use arms not exceeding
300mm in length.
2.Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling. 
						

							PANEL REPAIRS
PROCEDURES7REVISED:
3.Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4.MIG tack weld butt joints and re-check
alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.
5.Dress MIG tack welds using a sander with 36
grit disc, or a belt-type sander where access is
limited. 
						

							PANEL REPAIRS
8
PROCEDURESREVISED:
6.MIG seam weld butt joints.
7.Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot
weld cutter, or through holes punched and
drilled for the purpose.
8.Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required,
must be carried out at this point.