Separate deformed rear area - AR64.20-P-1200-11TA

Fig 1: Identifying Welding Spot Milling Cutter (201 589 00 51 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A	Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1001-40A	Tarp (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Identifying Body Cutting Area

Mark separation point and cut with body saw (areas A and B).
Expose spot welds and cut out with (area C).

Fig 3: Identifying Spot Welding Area
Cut out spot welds with welding spot milling cutter (area D).
Remove rear area.

Fig 4: Identifying Welding And Cutting Area
Cut out spot welds with welding spot milling cutter (areas E and F).
Remove rear center section. Mark separation points and cut with body saw
Mark separation points and cut with body saw (area G).
Remove longitudinal member section.

Fig 5: Identifying Spot Welding Area

Fig 6: Identifying Welding And Cutting Area
Cut out spot welds with welding spot milling cutter (areas H, I, J and K).
Remove longitudinal member section and left closing section.
Grind connection surfaces down to bare metal in shaded areas, grind spot weld flanges down to bare metal on both sides.
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 7: Identifying Grinding Surfaces Area Both Sides