41 00... Welding In Reinforcement Plate (Steel Plate)

In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.

A reinforcement plate is welded in to ensure sufficient strength.

NOTE: The following illustrations serve as general illustrations of reinforcement plate repair work. They are applicable to all cutting repairs.

Mark component in accordance with distance A and cut.

Fig 1: Identifying Component Distance Mark Between A And Cut

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Cut new part (1) in accordance with cut and if necessary adjust to fit with straightening attachment or universal mount.

Installation:

Adhere to a gap at severance cut of approx. one to max. two material thicknesses in order to ensure welding with the reinforcement plate and to facilitate a more tolerant fit.

Fig 2: Identifying Components And New Part

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Clean inner and outer sides of connecting areas (1) on new part and (2) on body.

Coat inner sides with welding primer.

Fig 3: Identifying New Part And Existing Body

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Drill holes (1) and (2) at distance of 25 mm to each other.

Hole diameter approx. 8 mm.

Fig 4: Identifying New Component Drill Holes And Drill Holes On Existing Body

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Make reinforcement plate (1) from trim of new part.

If necessary, make further reinforcement plates.

Length of reinforcement plates is min. 40 mm.

Fig 5: Identifying Reinforcement Plate From Trim Part

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Coat reinforcement plates (1) and (2) on both sides with welding primer.

Push reinforcement plate (1) into component on body up to half way and plug-weld (3).

Fig 6: Identifying Reinforcement Plates

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If necessary, adjust new part (1) to fit with straightening attachment or universal mount and plug-weld (2).

MAG weld joint (3).

Grind and clean weld seam and plug weld spots.

Only visible areas of the outer skin and worn areas on the support carrier must be tinned.

All areas which have covers on the vehicle are not to be tinned.

NOTE: Only applicable within the European Union!

European used-car regulations prohibit the use of tin containing lead in motor vehicles introduced after 01.07.2003!

Fig 7: Identifying New Part, Plug-Weld And MAG Weld Joint

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