SPS05-BDYMAN-E

Body Repair Manual

Structural Parts Steel

Program 5

CONTENTS
Making The Qualification Test PartOffset Fillet Weld Joints ................................................................ 3
Making The Qualification Test PartButt Joint With Backing Weld Joint ..........................................13

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

This body repair manual outlines the required steps for making the I-CAR Structural Parts Steel Qualification
Test part. The required welds include plug, fillet, and butt joint with backing.

MAKING THE QUALIFICATION TEST PARTOFFSET FILLET WELD

JOINTS
Step 1
Clean the parts with wax and
grease remover. Using a felt-tip
maker, mark in the middle of one
of the parts Replacement and
mark the other part Original.
Do this on both sides of each
part.

Step 2
On one side of the original part,
mark a cut line 75 mm from
the inside edge of the reference
holes that are located 50 mm
from the end of the part.

75 mm

50 mm

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 3
Mark 1AO to the outside
of the cut line and mark
2AO to the inside of the
cut line.

Step 4
Turn the original part over
and mark a cut line 180
mm from the inside edge of
the reference holes that are
located 50 mm from the end
of the part.

180 mm

50 mm

Step 5
Mark 1BO to the outside
of the cut line and mark
2BO to the inside of the
cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 6
Mount the original part in
a vise and carefully make the
cut at the 1B0/2BO side of
the part. Use caution to avoid
cutting through the mating
flanges on the 1AO/2AO
side when making the cut on
the 1B0/2BO side.

Step 7
Cut the 1AO/2AO side of
the original part, drill out
the four spot welds between
the 1AO/2AO and 1B0/2BO
cuts from the 1AO/2AO side,
and remove the end. When
drilling out the spot welds,
use caution to avoid drilling
through the mating flange
on the 1BO/2BO side. The
end that is removed, marked
1AO on one side and 1BO
on the other side, represents
the damaged part and can
be discarded.

Spot Welds

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 8
On one side of the replacement part, mark a cut line
85 mm from the inside edge
of the reference holes that
are located 50 mm from the
end of the part.

85 mm

50 mm

Step 9
Mark 1AR to the outside
of the cut line and mark
2AR to the inside of the
cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 10
On the other side of the
replacement part, mark a cut
line 205 mm from the inside
edge of the reference holes
that are located 50 mm from
the end of the part.

205 mm

50 mm

Step 11
Mark 1BR to the outside
of the cut line and mark
2BR to the inside of the
cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 12
Mount the replacement part
in a vise and carefully cut the
1AR/2AR side of the part.
Use caution to avoid cutting
through the mating flanges
on the 1BR/2BR side when
making the cut on the
1AR/2AR side.

Step 13
Make the required cut on
the 1BR/2BR side of the
replacement part, drill out
the four spot welds between
the 1AR/2AR and 1BR/2BR
cuts from the 1AR/2AR side,
and remove the end. The
end that is removed, marked
1AR on one side and 1BR
on the other side, will be the
replacement part.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 14
On the 1AR side of the
replacement part, cut off the
25 mm wide mating flanges,
10 mm from the end that
was cut off.

25 mm
10 mm

10 mm
25 mm

Step 15
On the 1BR side of the
replacement part, cut off the
25 mm wide mating flanges,
25 mm from the end that
was cut off.

25 mm
25 mm

25 mm
25 mm

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

Step 16
On the 1AR side of the
replacement part, make a
10 mm notch and bend the
overlap area as shown.

10 mm

Step 17
On the 1BR side of the
replacement part, make a
25 mm notch and flange the
overlap area as shown.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

25 mm

10

Step 18
On the 2BO side of the
original part, punch or dill
four 8 mm plug weld holes
in the overlap area. Plug
weld holes should be made
approximately 12 mm in from
the sectioning joint.

12 mm

Step 19
Test-fit the replacement part,
marked 1AR on one side and
1BR on the other, with the
original part and verify the
proper measurements. Trim
the parts as necessary for the
proper dimensions.
Step 20
Make practice welds using
the same type and thickness
of metal.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

253 mm

11

Step 21
Tack weld the replacement
part in place and verif y
the proper measurements.
Correct as necessary.

253 mm

Step 22
Using a combination of flat,
vertical, and overhead positions, make the required fillet
and plug welds to install
the replacement part. When
making the fillet welds, use
the skip or stitch technique
to avoid warping the part.
Allow the part to cool.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

12

MAKING THE QUALIFICATION TEST PARTBUTT JOINT WITH

BACKING WELD JOINT
Step 1
On one side of the original
part, mark a cut line 75 mm
from the inside edge of the
reference holes that are
located 125 mm from the end
of the part. The cut line should
be on the opposite end of the
side marked 1AR/2AO.

75 mm
125 mm

Step 2
Mark 3AO to the inside
of the cut line and mark
4AO to the outside of the
cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

13

Step 3
Make the required cut along
the 3A0/4AO cut line. Use
caution to avoid cutting
through the mating flanges
on the other side.

Step 4
Drill out the eight spot welds
on the 25 mm mating flanges
of the original part from the
3AO/4AO side of the part
and separate the two pieces.
Use caution to avoid drilling
through the mating flanges on
the other side. The piece that
was removed, marked 4AO,
represents the damaged part
and can be discarded.

Spot Welds

Spot Welds

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

14

Step 5
On one side of the replacement part, mark a cut line
75 mm from the inside edge
of the reference holes that
are located 125 mm from
the end of the part. The
cut line should be on the
opposite end of the side
marked 2AR.

75 mm

125 mm

Step 6
Mark 3AR to the inside
of the cut line and mark
4AR to the outside of the
cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

15

Step 7
Make the required cut along
the 3AR/4AR cut line.

Step 8
Drill out the eight spot welds
on the 25 mm mating flanges
of the replacement part from
the 3AR/4AR side of the
part and separate the two
pieces. The piece that was
removed, marked 4AR, will
be the replacement part.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

16

Step 9
On the other side of the
replacement part, mark a cut
line 100 mm from the end
of the part.

100 mm

Step 10
Mark Insert to the outside
of the cut line.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

17

Step 11
Make the required cut along
the Insert cut line.

Step 12
Cut off the 25 mm mating
flanges on the insert to
create an approximately
100 x 80 x 80 mm insert.
Some trimming may be
required to ensure proper
fit-up.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

18

Step 13
Install the original part,
marked 3AO, in a vise or
welding fixture and test-fit the
replacement part, marked
4AR, and insert leaving a root
gap of 24 metal thicknesses.
Verify the proper measurements. Trim as necessary.

179 mm
Step 14
Remove the replacement part
and insert from the original
part. Punch or drill four 8 mm
plug weld holes in the original
part, marked 3AO, in the area
that will overlap the insert.
Also punch or drill four 8
mm plug weld holes in the
replacement part, marked
4AR, in the area that will overlap the insert. Plug weld holes
should be made approximately 25 mm in from the
sectioning joint.

25 mm

Step 15
Make practice welds using
the same type and thickness
of metal.

12 mm

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

19

Step 16
Fit-up and clamp the insert
into the original part, marked
3AO. Plug weld the insert
into the original part. Allow
to cool.

Step 17
Test-fit the replacement part,
marked 4AR, with the original
part and insert leaving a root
gap of 24 metal thicknesses.
Verify the proper measurements. Trim as necessary.
Step 18
Make practice welds using
the same type and thickness
of metal.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

179
179 mm
mm

20

Step 19
Tack weld the replacement
part in place and verif y
the proper measurements.
Correct as necessary.

179
179 mm
mm

Step 20
Using a combination of vertical and flat positions, make
the required butt joint with
backing and plug welds to
install the replacement part.
When making the butt joint
with backing weld, use the
skip or stitch technique to
avoid warping the part. Allow
the part to cool.

Structural Parts Steel Program 5 v.4.1

2002 Inter-Industry Conference On Auto Collision Repair

21