Unibody: Service and Repair
NON-STRUCTURAL SHEET METAL REPAIR
Side Aperture / Quarter Panel
Overview: Chrysler's recommended repair procedure for body side aperture / quarter panel replacement include butt joints using backer panels with structural adhesive at the sectioning joint, or a welded backer panel with a welded butt joint using GMAW (Gas Metal Arc Welding). Resistance spot welding with structural adhesive, referred to as weld bonding, should be used at all pinch welds and may be used at the drain trough and tail panel areas as well. With the exception of the sectioning joint, the rule to follow is "Re-assemble as it was built from the OEM". For further information on Weld / Weld Bonding, (Refer to 31 - Collision Information - Standard Procedure) GMAW (plug or puddle) welds may be used in place of STRSW (Squeeze Type Resistance Spot Welding) only in areas that specifically use spot welds and in areas that access limitations will not allow STRSW. GMAW cannot be used in the weld bonding process. Never weld with GMAW within 25mm. (1in.) of any area where structural adhesive is used. The weld "heat zone" will destroy the properties of the adhesive.
Vehicle design will determine if the sectioning location is to be in the pillar or the roof line area. For locations and warnings that may apply to body side aperture / quarter panel sectioning locations reference Sectioning Procedures.
Preparation:
NOTE: Be certain vehicle is evenly supported at normal suspension points.
1. Restore structural dimensions as well as all related mating flanges.
2. Once sectioning locations have been established, cut original and replacement panels at the pre-determined locations. Remove spot welds within sectioned parameter.
NOTE: Be careful not to destroy any areas that may be able to be used as backer panels.
3. If panel is attached with adhesive, you may use heat, from a non-flame heat source, up to 204�C. (400F�). This will aid in loosening the bond.
4. Use an air chisel with a flat bladed bit to remove original panel.
5. Using a hammer and dolly, restore any and all damage to mating surfaces.
6. Create backer panels to be used at butt joints. Refer to Backer Panel Joint, (Refer to 31 - Collision Information -Standard Procedure).
NOTE: It will be difficult to abrade the underside mating surface of the original panel, where backer panel is to be used, however this is important step and should be done effectively.
7. Grind all mating surfaces with a 50 grit grinding disk. Remove all adhesive, sealers, paint, E-coating and corrosion protective coatings from the area where the structural adhesive and welds will be applied. The metal should be completely bare and shiny in appearance, if the metal appears pewter in color all of the galvanized coating has not been removed.
8. Pre- drill any GMAW plug / puddle weld holes that may be necessary, with a 8mm. (5/16in.) hole.
9. With the aid of an assistant, dry fit the panel. Apply clamps to hold panel in place, making note of locations. Install screws where accessibility prohibits the use of clamps. This will aid in proper alignment during installation.
10. Without a mixing tip installed, purge a small amount of structural adhesive from the cartridge. This will ensure an even flow of both components.
11. Attach a mixing tip and dispense a mixing tube's length of adhesive from the cartridge.
NOTE:
- Using scrap metal and adhesive, make test coupon samples and perform peel test to ensure your STRSW equipment is ready to apply welds as required. The Weld/Weld Bonding section will provide further information on peel testing and equipment set-up.
- Refer to the structural adhesives manufacturer for information on work, handling and curing times.
Installation:
12. Install backer panels, refer to Backer Panel Joint.
13. Apply 10 - 13mm (3/8 - 1/2in.) bead of structural adhesive to the area where the two panels are to be bonded and weld bonded. Do not apply to areas that will only be STRSW or GMAW welded.
14. Smooth the adhesive with a body filler spreader or equivalent, to cover all bare metal surfaces. Apply a second bead of adhesive to ensure proper adhesive thickness.
15. With the aid of an assistant place the panel to the vehicle. If the panel needs to be adjusted, slide the panel.
NOTE: Adjustments must be made by sliding, not lifting the panel(s). Lifting will cause air bubbles and weaken the bond.
16. Install clamps and screws to locations determined during the dry fit process.
17. Remove all squeeze out of adhesive, prior to curing.
NOTE: Structural adhesive manufacturers will vary on time allowed for completion of STRSW in weld bond zones. Check and follow adhesive manufacturer recommendations.
18. Apply STRSW to weld bond area immediately.
19. Once fully cured, remove clamps and screws. When fully cured, expect adhesive to remain a little tacky, as this is a normal characteristic of the adhesive.
20. Complete STRSW and / or GMAW (plug / puddle ) welds.
21. Finish / Dress the welds as necessary. If screws were necessary bevel the screw holes. Prepare the joint and screw holes by grinding the area with 50 grit grinding disc. Get in seams as best as possible without thinning the metal.
22. Remove any excess cured adhesive with a grinder or abrasive disc. All adhesive must be removed from the cosmetic repair area to ensure proper adhesion of repair and refinish materials.
23. Apply fiber-reinforced waterproof body filler to screw holes and joint. Complete the repair using conventional body filler, and block sanding.
24. Apply an epoxy or anti-corrosion primer. When cured, lightly scuff and then apply seam sealer as necessary.
25. Prime and paint per paint manufacturer recommendations.
26. Apply inner panel corrosion inhibiting materials (Mopar Cavity Wax part #68042970AA, or equivalent).