Repairing Major Body Damage - Parts Replacement
1. Parts Replacement
1.
Cutting welded joints:
Spot welding is mostly used for the mass produced body welding. MAG welding may also be used occasionally.
When separating the weld joints, use hole punching and grinding tools according to the joint conditions.

Confirm the assembly status of the replacement panels and make sure not to damage the parts being reused.
Cutting spot welded joints:
Remove the weld nuggets.
Cutting MAG Welded joints:
Remove the weld beads and plugs.
2.
Repair the interfacing areas and apply anti-rust treatment.
?1.
Reform the weld flange where the new parts will be installed using a hammer and a dolly. Repair holes and cracks by welding if the steel grade allows this. Otherwise replace the damaged part.
?2.
Sand the both sides of welding area using a belt sander to remove basecoats, rust and contamination.

Do not over-sand the welding area.
?3.
Anti-rust treatment
Thoroughly apply electrically-conductive weld through primer (spot sealer) evenly on the mating surfaces in the welding area.
3.
Installing new parts and anti-rust treatment.
Spot Welding of a New Part:
?1.
Remove basecoat (E-coat primer) layer
Basecoat (black E-coat primer) is applied to new parts. Completely remove this basecoat in the weld areas prior to welding.

Do not over-sand the steel panel.
?2.
Anti-rust treatment
Thoroughly apply electro-conductive weld-through primer (spot sealer) evenly on the areas to be spot welded after removing the paint and E-coat.
Wipe off excess primer.

Plug Welding a New Part:
Place holes for plug welding on the new part using a drill or hole punch.
Decide on how many holes to be made according to the mass production body welding drawing in the model specific body repair manual or the old part.
Refer to “MAG welding for plug welding” for the appropriate hole diameter as compared to panel thickness.

2. Zinc-Plated Steel Parts Repair

Zinc-Plated Steel Parts Repair

The zinc-plated steel plate used in some panels of the Honda and Acura vehicles requires different repair techniques and personal safety protection than ordinary steel plate. Refer to body construction information in “General Information” of the model specific body repair manual to determine which parts are zinc plated.

Zinc fumes are generated during grinding and welding of zinc-plated steel parts and the application of weld-through primers (spot sealer). This can cause an illness known as “metal fume fever” that causes temporary flu-like symptoms. Additional health problems may result from long-term exposure to zinc fumes. Always use approved respiratory protection that provides zinc fume protection when working around zinc plated steel and weld-through primers (spot sealer).
1.
Before spot welding the zinc-plated steel, remove the paint or E-coat from both sides of the flanges being welded. Apply weld-through primer (spot weld sealer) to the flanges before welding.
NOTE: Seal the sanded surfaces thoroughly to prevent rust.
2.
Before applying body filler or putty to zinc-plated steel, sand the zinc plating thoroughly. Apply epoxy primer to promote adhesion and prevent blistering.
NOTE: Use body filler and putty (one part filler/putty, one part harder), that are compatible with zinc-plated steel and follow the manufacturer’s specifications.

3. Parts Installation
1.
Sectioning the new part (cut and joint replacement).

Before sectioning any part, check the Parts Sectioning (Cut and Joint) Guidelines in the Repair Overview section of this manual for important information.
If a new part, such as an outer panel, is being sectioned, cut the old and new parts using an air saw or grinder, so that the joint area can be overlapped about 20-30 mm (0.79-1.18 in).
When there is an acoustic separator on the panel mating surface:
Damaged separators should be replaced with a new one. The replacement separator does not include the heat-activated expandable foam used in production. Apply body sealer around the separator to fill in the gaps between the separator and body panels.
If you make your cuts with too much body overlap, it will be difficult to position the replacement panel for fit and finish.
2.
Positioning the new part:
Align the new part to body reference holes, or old part position and attach it to the body using clamps, vise-grip type pliers, or other commercially available panel attachment tools.
If these tools are not available, attach the new part using bolts or self-tapping screws.
Measure the body dimensions to confirm panel positioning.
It is extremely important to attach the frame and damper housing parts to the correct positions because they directly affect wheel alignment. (It is recommended to use jig-type body and frame correction equipment or those with built-in measurement systems for greater accuracy.)
Fit and finish of exterior parts is also extremely important as it will greatly impact the exterior appearance. Make sure to install all exterior parts for a final confirmation before permanent attachment.
3.
Welding the new part.

Cover the interior accessories, glasses and body painted surfaces with the heat-resistant inflammable cover (welding blankets) to protect them before welding.

Key Points For Spot Welding:
Using vise grip type pliers or similar tools, clamp the welding areas tightly with no gaps.
Try to avoid the old spot welds as much as possible and place them with an even pitch.
For the areas that cannot be spot welded, use MAG welding or MIG brazing instead if permitted. Always follow the welding instructions for high strength steel parts in the Repair Overview section of this manual.
Dress the spot welder electrode tips to maintain their condition using a tip cutter. Replace the tips when dressing them no longer restores proper appearance and function.
When welding, refer to the specifications in the manual issued by the welding equipment manufacturer.

Key Points For MAG Welding:

Be sure to attach the welder’s ground cable as close as possible to the welding area.
Using vise grip type pliers or similar tools, clamp the welding areas tightly with no gaps.
If these tools cannot be used because of space limitations, use a hammer and dolly to make tight contact.





Examples of acoustic separator installation locations
4.
Inspect the welded area
Thoroughly inspect the welded area to ensure all required welding operations are completes before finishing.
5.
Finishing the welding:
To finish, grind the plug or joint welded area with an angle grinder or equivalent.
Do not over-grind to prevent weakening the welds.
In glass contacts areas, completely remove any steps or projections.
Apply body filler to finish butt welded areas.
?
Avoid separator installation points when repairing, cutting and welding panels. If the separator’s urethane foam is damaged (peeled or burnt), restoration is not possible.
?
Damaged separators should be replaced with a new one. The replacement separator does not include the heat-activated expandable foam used in production. Apply body sealer around the separator to fill in the gaps between the separator and body panels.