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– 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).
7.6.3 Creating an FDS joint (when renewing
upper and lower panels)
– Remove flow-drill screws using socket for flow-drill screws and
separate joint.
– Take off both panels.
– Drill 4 mm Ø holes in both panels at the same distances as on
the original joint.
– Detach new parts.
– Drill out 4 mm Ø holes in upper panel to 7 mm Ø.
– 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).
Repair kit for FDS joints
The repair kit can be used to mark the holes on new parts where
flow-drill screws (FDS) are used. With the aid of the hole finders,
it is possible to transfer the FDS hole positions on aluminium Audi
vehicles when making repairs. The old FDS screws are first loos‐
ened with the aid of the socket. The damaged panel is then
removed. Using the ring spanner (supplied with the repair kit), the
hole finders are now screwed into the existing holes in the alumi‐
nium panel not being renewed. The new aluminium panel is then
fitted on the vehicle and fixed in position with clamps. Using soft
blows with a rubber hammer, the holes from the existing panel
can now be transferred to the replacement part with the aid of the
hole finders. After being marked with the hole positions, the re‐
placement part is removed. Holes are predrilled at these points.
It is then possible to secure the new part to the body with flow drill
screws using the socket.
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
General InformationBody Repairs, General Body Repairs - Edition 04.2018
7. Cold joining techniques 47
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