Automotive Body Panel Replacement: Pillar, Door, Quarter Panel, and Rocker Panel Repairs
Total Front Pillar Replacement: Citroën BX
In this vehicle, the majority of parts are replaced in full, though partial replacement is also common. Here are the steps for removal and replacement:
Removal Steps
- Remove the front fender, rubber door edge, safety belt, and door.
- Protect seats and the vehicle interior.
- Remove trimmed welding points.
- Operations include surface flattening, deburring, removal of welding debris, and primer application.
New Part Placement and Welding
- Place the new item after replacement, ensuring removal of electrocoating primer from tabs.
- Apply electrofusion.
- Position and adjust the new piece, securing it with clamps and plug welding points.
- Check the alignment of front and rear doors.
- Use a suitable restraint to correctly position the pillar before welding.
- Perform resistance spot welding and MAG plug welding.
- Finally, perform MAG welding and cord welding in the upper area of the pillar.
- The last operation is the application of cavity wax inside the pillar to prevent water intrusion.
Complete Door Panel Replacement: Opel Kadett
This procedure details the complete replacement of an Opel Kadett door panel:
- Remove the trim.
- Remove the plastic waterproofing.
- Dismount the window and accessories.
- Remove hinge pins.
- Remove the door and place it on a support.
- Deburr the door edge with a radial grinder.
- Remove broken sealant cord and resistance welding points.
- Remove the frame tabs.
- Break off the door panel with a chisel.
- Remove the panel.
- Remove sealant around the frame edge.
- Remove residual solder.
- Prepare tabs.
- Apply zinc primer to the entire area.
- Place the frame on the panel.
- Secure it with clamps.
- Perform folding.
- Adjust the door.
- Perform hemming.
- Fit the door.
- Clean the electrode contact area with a clean strip.
- Apply resistance spot welds where original.
- Apply polyurethane sealant.
- Paint the door.
- Fit the door.
- Mount attachments.
- Apply wax in the interior cavities and perform final assembly.
Complete Rear Quarter Panel Replacement: Suzuki Vitara
This section outlines the process for replacing the rear quarter panel of a Suzuki Vitara:
- Once trims and accessories are removed, eliminate existing spot welds.
- Measure and mark cutting areas.
- Then, carefully detach and unclip to avoid damage.
- Remove unclipped points with a chisel.
- Remove loose material, tabs, and coatings.
- Prepare the replacement body panel.
- At the joint, create a stepped overlap with fillet pliers.
- Apply a structural adhesive, spreading it over the entire joint.
- Once the replacement is in place, begin welding the bracket and the roof pillar.
- Resistance spot weld the tabs.
- Then, perform welds in the overlapping area.
Rocker Panel Replacement: Fiat Punto
This procedure details the replacement of a rocker panel under a Fiat Punto door:
Panel Cutting
- Start cutting the top with a cold chisel and hammer.
- Continue along the door frame and the central pillar.
- Cut the panel with a hand saw.
- Use a pneumatic hammer to cut along the lower cut line.
- Continue the cut near the center pillar.
- Continue cutting to the previous section.
Cut Removal
- Remove sealant residue.
- Reduce the size of soldering points.
- Remove plate cuts and straighten edges.
- Remove remaining spot welds.
Replacement Preparation
- Remove anti-corrosion treatment from front and back.
- Apply electro-galvanizing paint.
Spare Part Placement
- Draw the profile of the replacement body panel.
- Cut the overlying plate.
- Cut the replacement panel.
- Remove excess cuts.
Edge Preparation
- Straighten the edges.
- Remove traces of soldering points and level edges.
- Apply electro-galvanizing paint.
Parts Preparation
- Attach a threaded fastener.
- Place the parts and secure with solder.
- Mount provisionally.
Finishing Operation
- Remove welding slag.
- Correct distortions and apply anti-corrosion treatment.