PANEL REPAIRS
1
PROCEDURES 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:
Torch liner (Teflon or Carbon Fibre)
Contact tip
Feed rollers/wheels
Correct Filler wire (combination of
Aluminium and Magnesium)
Shielding gas (Argon)
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.
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.
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:
A. MIG Plug welds
B. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications.
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.
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.
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.
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