Joining Techniques

501-25 Body Repairs - General Information 2016 Mustang

General Procedures Procedure revision date: 05/21/2012

Joining Techniques

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment

Grinder

Plasma Cutter

Air Body Saw

8 mm Drill Bit

MIG/MAG Welding Equipment

Spot Weld Drill Bit

Materials

Repair

1. WARNING: Before beginning any service procedure in this section, REFER to Safety Warnings

in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).

2. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.

3. Remove damaged panels. Remove only large portions of the damaged panel. Avoid cutting into mating flanges or adjacent parts. Use the General Equipment: Air Body Saw Use the General Equipment: Plasma Cutter

4. Drill out the spot welds and remove the remaining portions of the panel to be replaced. Use the General Equipment: Spot Weld Drill Bit

5. Prepare any damaged flanges on the vehicle using hammer and dolly.

6. Grind the mating surface of the original flanges no greater than 25 mm (0.9843 in) where the metal bonding adhesive will be applied.

7. Be sure to remove galvanizing on metal. Metal should have a shiny appearance. Be careful not to damage