Make Weld Seam On Vehicles With Aluminum Body - Ar60.00-P-0070-01S

Model 192 

Model 223.0/1/9 

Model 232 

The superordinate service document as well as the safety information in the service document must be observed.

Manufacturing backing strips (1), shown using the right rear fender in the area of the C-pillar 

1. From the remaining pieces of the new part, manufacture backing strips (1) with a width of approx. 40 mm.

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2. Insert backing strips (1) at repair point and fit.

   It must be possible to insert backing strips (1) without tension and such that they lie flat.

   Otherwise, the strength of the MIG weld seam cannot be guaranteed and the new part may warp severely during welding.

3. Remove coatings on new part and body in area of MIG weld seam.

   Use a suitable grinding material that will not remove any aluminum.

   Fixing backing strips (1) without tension, shown on the top B-pillar paneling 

   The fixing of the backing strips (1) is shown on the body and must be carried out in the same way on the new part.

   If there is sufficient distance from the components underneath, backing strips (1) are fixed using bolts (round head bolts made from stainless steel).

   In exceptional cases (limited space available), the bolts are replaced by plug welds.

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4. Insert backing strips (1) at repair point and fix in place.
5. Drill holes for the bolts in the body and in the backing strips (1).

   Always drill a hole at the beginning and end of the backing strips (1). Drill the remaining holes at intervals of approx. 4 mm.

   Ensure that there is sufficient distance between the drilled holes and the separating point.

   The size of the drill bit depends on the bolts used.

6. Remove backing strips (1).
7. Drill holes in body with Ø 1.0 mm larger bit.

   This ensures that the backing strips (1) can be fixed in place using bolts without tension and that the new part will not warp during welding.

8. Secure backing strips (1) with screws.

   Screws must not make contact with component parts below.

   Otherwise, the backing strips (1) will not lie flat against the new part and the strength of the MIG weld seam cannot be guaranteed.

   Tack backing strips (1), shown on lower B-pillar paneling 

9. Clean separating point with a stainless steel brush immediately before tacking.
10. Tack backing strips (1) to edges and at a distance of approx. 4 mm.

    Do not grind the tacks down flat.

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    Creating an MIG weld seam, shown on the bottom B-pillar paneling 

11. Clean separating point with a stainless steel brush immediately before welding.
12. Create MIG weld seam.

    Create MIG weld seam in a single uninterrupted process.

    Creating plug welds, shown on the bottom B-pillar paneling 

13. Remove a bolt.
14. Clean separating point with a stainless steel brush immediately before welding.
15. Create plug weld.

    Set the output of the welder for the double material thickness.

16. Repeat operation steps  13 to  15 for all screws.

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    Creating the surface at the separating point, shown on the bottom B-pillar paneling 

17. Grind MIG weld seam and plug welds flat.
18. Restore surface in the repair area with basic body filler.

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