Mix and apply basecoat per paint manufacturer's recommendations.
19. Mix and apply clearcoat per paint manufacturer's recommendations. Refinishing materials may be force-
dried following paint manufacturer's recommendations.
20. Apply rust inhibitor or undercoating as required to provide corrosion protection to the repair area.
Weld-Bonding — Metal Inert Gas (MIG) Welding Method
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and
skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing
adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear
flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious
personal injury.
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and chemically
resistant gloves. Failure to follow these instructions may result in serious personal injury.
WARNING: Always wear protective equipment including eye protection with side shields, and a dust
mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
NOTE: Metal Inert Gas (MIG) weld-bonding can be substituted as an alternative to Squeeze-Type Resistance Spot
Welding (STRW). It may only be used to weld areas that are inaccessible to STRW machinery. However, when
accessible, STRW is the preferred method.
NOTE: Corrosion protection needs to be restored whenever it is necessary to grind through painted surfaces or E-
coat, or when bare metal repairs are made. For additional information, refer to
Restoring Corrosion Protection
Following Repair in this section.
NOTE: Factory spot welds should be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds
should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld
location.
Plug weld hole should equal 8 mm (0.31 in) diameter.
1. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
2. Depower the High Voltage Traction Battery (HVTB) before carrying out any removal or installation
procedures affecting the high-voltage battery system. Refer to Section 414-03
for the correct procedure to
depower the HVTB system on hybrid-equipped vehicles.
3. Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged panel.
Avoid cutting into mating flanges or adjacent parts.
• Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining portions of
the panel to be replaced.
4. After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a
hammer and dolly.
5. Using an appropriate grinder, carefully grind around the entire receiving flange area following the original
welds. Be sure to remove all E-coat, paint or galvanized coating from the mating surfaces of the joint.
• Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
• Be careful not to damage the corners or thin the metal. The E-coat should also be removed on the
opposite side of the flange only where the spot welds are to be placed.
6. Repeat the procedure from Step 3 on the mating surface of the replacement service part(s).
7. Prepare the new service panel for plug welds.
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