Spot Weld Removal example essay topic

The 1996 Mercedes E 320 sustained crash damage to the passenger side front. After we set up and measured the vehicle on the caro-liner frame rack, we found there to be extensive panel, sub frame, and suspension damage. Including consequential interior damage, IE; Driver / passenger airbags deployed, dash panel assembly, and passenger airbags deployed, dash panel assembly, and passenger side mirror. After a complete damage assessment report, we then began disassembly of all damaged panels and assemblies. After the disassembly we decided which parts would be salvaged off of our 1997 Mercedes E 320, which parts would be purchased new or those which would need to be straightened and refinished. Once the damaged panels were removed we were able to attach the 10-ton hydraulic ram assembly to the frame rack and began the frame straightening repairs.

Our initial pulls were to fix the sway problem of the passenger side front sub frame. This was accomplished by wrapping a chain around the misaligned sub frame, pulling in a straight, level manner opposite the direction of the misalignment. We did several pulls in this manner, stress relieving, before and during, with a ball peen hammer before repositioning for the next pull until brought back into specification. We then positioned our 10-ton ram to the passenger front for repair of the frame rail mash and sag situation sustained on impact. We wrapped the chain around crash impact bar and used it as the hook up point for our pulls.

Pulling and stress receiving until it also was within specifications. Our final pull was to the suspension passenger side A-arm. We simply attached our chains to the A-arm and pulled it back into position. At this point, we could now begin sectioning and panel removal.

This was first done by deciding which panels were to be removed and which were to be repaired. Then all of the spot welds that needed to be removed were marked with a paint marker, so as to only to remove the necessary welds. Some spot welds were located underneath seam sealer and or insulation. We then removed the material with a hand torch to burn the seam sealer, then a steel bristled brush to scratch off the burnt material. We then center drilled all of the marked spot welds with an 1/8" drill bit, followed up by a 5/16" spot weld removal bit to drill out the spot welds along all of the panels to be removed. Being careful using the drill and drill bit, only removing the necessary layer of the panel.

With all of the spot welds, seam sealers, insulation, and related parts removed or moved out of harms way, we then removed all of the damaged panels which included the passenger side wheel apron, suspension cross member, and the front impact bar using air chisels and hammers. All of these pieces were then removed from the 1997 Mercedes E 320 parts vehicle in the same manner as removed from the 1996 Mercedes E 320. The salvaged parts were then cleaned and repaired as needed. We then positioned the panels onto the 1996 vehicle using screws and or clamps.

We then plug welded the spot weld holes that we had drilled out earlier with the mig welder. Some holes, such as on the impact bar and suspension cross member. We had to enlarge the plug weld holes slightly as to get more penetration with mig welder, so as to avoid any problems with the welds failing in the event of another collision. After all of the panels were welded, seam sealer, insulation, wiring, accessories, and corrosion protection were put back to original factory condition. With all of the frame, suspension, and under panels repaired attention was the turned to the engine and transmission.

Both the engine and transmission were checked, and tested for damages sustained in the crash. The damaged pieces were then replaced and full diagnostics were performed to test and confirmed that all repairs were completed. Now began the process of putting the cars exterior and interior back to the factory fit and finish. We began by first putting the driver and passenger front doors back into the position adjusting to proper fit and operation.

Next were the front fenders, adjusting to the leading edge of the doors. The new bumper cover, hardware, i.e. (clips, fasteners, etc), headlight / fog light assemblies, exterior trim, and passenger mirror were then reinstalled per the factory specifications. The hood, including all of its assemblies were then installed, adjusted, and checked for proper closing and latching. At the same time that the exterior was being buttoned up, the interior was reassembled. Replacement air bags, passenger / driver were installed, including the resetting of any and all computer trouble codes. Stereo components, electronics, and interior trim were all reinstalled.

After installation, all components were checked and tested for proper fit and operation, per factory guidelines. The vehicle was then checked over again, for fit and finish. Then any necessary adjustments or bodywork was completed. After the final inspection, the car was returned to the owner with the keys and a fresh coat of wax..