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7.6 Flow-drill screws (FDS)
When flow-drill screws are used, the lower component is heated
up by the frictional heat generated by the screw as it is turned.
The self-tapping flow-drill screw is then screwed into the soft alu‐
minium.
Maintenance of joints where flow-drill screws (FDS) are used:
Note
♦
The Audi R8 employs flow-drill screws which can be renewed
using socket for flow-drill screws - VAS 852 007- .
♦
The repair methods required for the all-aluminium body parts
are the same as the existing methods for the other Audi mod‐
els with aluminium body.
♦
The advantages of threaded fasteners for workshop repairs
can now be used to the full with the aid of this tool.
The process for creating an FDS joint is illustrated below using
three different examples.
7.6.1 Creating an FDS joint (upper panel with
pre-drilled holes)
– Remove flow-drill screws using socket for flow-drill screws and
separate joint.
– Take off upper panel.
– Prepare joints for adhesive application.
– Clean bonding area with cleaning solution.
– Prepare bonding area with silicate stone and clean.
– Apply aluminium primer to bonding surfaces using applicator.
– Apply 2-component epoxy adhesive to entire area using pneu‐
matic glue gun.
– Fit new part in position and secure with new screws using
socket for flow-drill screws (tighten to 5Nm).
7.6.2 Creating an FDS joint (upper panel with‐
out pre-drilled holes)
– Remove flow-drill screws using socket for flow-drill screws and
separate joint.
– Take off upper panel.
– Insert hole finders into existing FDS threads.
– Fit new part in position.
– Mark holes on new part with light blows from a rubber-headed
hammer.
Note
Allow for offset resulting from hole finders; if necessary mark just
one surface at a time.
– Take off upper panel.
– Drill 7mm Ø holes in new part.
General InformationBody Repairs, General Body Repairs - Edition 04.2018
46 7. Cold joining techniques
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