DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS
CHASSIS INTERVENTIONS
2.2 DRILLS ON THE CHASSIS
9
– Printed 692.68.999 – 3 Ed. - Base 08-2020
● if an electric circuit breaker (main switch) is present, wait for it to complete the cycle;
● disconnect the negative pole from the battery;
● disconnect the positive pole of the battery without connecting it to ground; do NOT short-circuit the negative pole;
● disconnect all ECU connectors, proceed with caution and do not touch the ECU connector pins;
● disconnect the ECU from the vehicle for welds close to the ECU;
● connect the welder ground directly to the weld piece;
● protect the plastic pipes from heat and disconnect them if necessary;
● protect the surfaces of the leaf and air springs against any weld splashes when welds are performed nearby;
● avoid touching the spring leafs with the electrodes or pliers.
Weld operations
● Cut the side members with a skewed or vertical cut. Cuts are not permitted in areas where there are a high concentration of
stresses (e.g. spring brackets). The cutting line must not go through the holes on the side member (see Figure 4).
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Figure 4
● Make a 60 degree bevel cut on the internal part of the side member of the parts to be joined, along the entire length of the
weld area (see Figure 5).
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Figure 5
● Arc weld the area with multiple steps and use base electrodes that are thoroughly dried.
Avoid power overloads; the welds must be free of marginal incisions and slag.
● Let the side members cool slowly and in a uniform fashion. No cooling with air jets, water or other means is allowed.
● Grind off the excess material.
● Mount steel corner reinforcements that have the same characteristics as the chassis; the minimum indicative sizes are shown in
Figure 3.
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