Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Partial Renewal

The procedure to follow when partially renewing components is the same as described in the section "Welded Components".

The main difference when components are partially, rather than completely renewed, concerns the preparation of butt or lap joints.

  • When bodywork components are cut through, attention must be paid to the adequate removal of the paint and zinc coatings on inner areas. This specially applies to areas which are difficult to access internally.
  • It is important for the weld quality that the inner area is bare metal. Zinc and paint residues in the weld area burn and cause serious hole formation during welding.
  • If the zinc layer and the paint coating are not removed, the zinc and paint will burn during welding. The soot produced prevents satisfactory cavity protection.

Procedure

  • The paint layer must be removed for a width of 30 mm from the line of the weld using a rotating tress wire brush.
  • This operation must be carried out on both the new and the old parts of the bodywork.
  • Depending on the bodywork component, a 10 mm width of the underlying zinc layer must also be removed along the weld line.

NOTE:

A flat scraper or a wire brush can be used instead of the rotating brush if the cavity is small. Do not use an angle grinder, which would reduce panel integrity and may weaken the structure.

Application of Cavity Wax Protection on a Door Rocker Panel After Partial Repair

Application of Cavity Wax Protection on a Door Rocker Panel After Partial Repair

  1. Weld bead
  2. Spray head
  3. Distance maintainer
  4. Spray gun

Classification of the different corrosion protection measures for dent removal

Classification of the different corrosion protection measures for dent removal

Classification of Different Corrosion Protection Measures for Installation of New Components

Classification of Different Corrosion Protection Measures for Installation of New Components

Classification of Different Corrosion Protection Measures for Installation of New Components

BODY SEALING MATERIALS

BODY SEALING MATERIALS

  1. Between Panels - Bolted
  2. Panel Edge Bolted
  3. Between Panels - spot welded
  4. Panel edges - spot welded
  5. Between panels - bonded
  6. Panel edges - bonded
  7. Clinch joints - type A
  8. Clinch joints - type B
  9. Clinch joints - type C
  10. Gaps between panels - type A
  11. Gaps between panels - type B
  12. Lap joint

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