PANEL REPAIRS
GENERAL WELDING PRECAUTIONS
The following pages show the procedures to follow
when using welding for repairs. No resistance spot
welds have been used in any of the repairs.
The Aluminium alloy used on all Defender models is a
combination of Aluminium and Magnesium.
When converting a MIG welder for use on Aluminium
it is essential the following components are changed.
The materials shown in brackets are the correct
materials to use:
A. MIG Plug welds
•
•
•
•
Torch liner (Teflon or Carbon Fibre)
Contact tip
B. MIG seam weld
Feed rollers/wheels
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications.
Correct Filler wire (combination of
Aluminium and Magnesium)
•
Shielding gas (Argon)
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
When carrying out welding operations the following
criteria must be observed:
•
Where resistance spot welds have been
used in production, these must be replaced
with either MIG plug welds or rivets.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds. A crack
detection process must be carried out in these areas.
•
To replace each production spot weld an 8
mm (0.31 in) hole must be drilled and/or
punched, and a MIG weld then made in its
place. The number of plug welds must
match exactly the number of spot welds
which have been removed.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
•
Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.
•
•
When MIG welding ensure the correct wire
is used.
The replacement welds in the welding
diagrams are denoted by the following
symbols:
PROCEDURES
1
| Categories | Land Rover, Land Rover Defender |
|---|---|
| Tags | Land Rover |
| Model Year | 1999, 2000, 2001, 2002 |
| Download File |
|
| Document Type | Workshop Manual |
| Language | English |
| Product Name | Defender |
| Product Brand | Land Rover |
| Document File Type | |
| Publisher | landrover.com |
| Wikipedia's Page | http://en.wikipedia.org/wiki/Land_Rover |
| Copyright | Attribution Non-commercial |
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