GEELY MK 2008 Workshop Manual

(f). Flatten the edge with hammer or sizing block, and remove the burr with file to make sure that it is aligned
with the both side alternative plates with a clearance not more than 1mm;
(g). Replace the plate, and clamp it with pincers. Carry out the spot welding along the seam at a space of
approximately 50mm;
(h). Make the welding from the center to both sides alternately block by block. Which can reduce the
deformation;
(i). Strike the welding line with the hammer or sizing block to remove the retaining stress. Polish the welding
lien wit the file or manual grinding wheel to make it even and smooth for the painting.
c. Repair for Accidented Damage
(a). Plate work flattening
When the accidented damage occurs on the plate work of the body, it can be repaired by means of beating.
In the repair process, start from Point C as shown in Fig. 5-26. Put the sizing block on the convex point, and beat
it with the hammer and change the block's position correspondingly. When the convex point is flattened, the
concaved part in Point B will rise. Similar wit the original profile of the plate, for the remaining dent, a sizing block
with the same radian can be employed. Press the bottom of the plate with hand, and beat the high point of the dent
with the hammer. (Fig. 5-27)Fig. 5-27 Plate Work Flattening (II)
A. Hammer B. Plate work
C. Sizing block Fig. 5-26 Plate Work Flattening (I)
A. Impact point B. Concaved point after impact
C. Convex point after impactFig. 5-28 Heating & Planishing
Convex Point
1. Heating pointBody Repair -Repair After Body Damage7-19 In the beating process, beat the work piece heavily at the beginning and lightly at the end. Attention shall
be paid to reduce the number of beating as possible as it can. Don't beat the same points repeatedly to prevent the
metal plate extending locally, which can complicate the repair work.
For the larger arc concave, a sizing block can be used under the center of the concave. The area of the sizing
block shall be a little larger. Jack the concaved plate up with a supporting tool. Sometime, heat the concaved part
to wine color to reduce the force. When jacking the plate up, a little excess is acceptable. (Fig. 5-28)
(b) Thermal contraction
When the concave is jacked up, if the plate extends seriously and the area is large, the thermal contraction
method can be used in case that the traditional methods don't work. (Fig. 5-29)
Heat the work piece to cerise color with oxyacetylene flame. The heating scope depends on the degree of extension.
If the extension is serious or the area is large, the heating point shall be larger relatively (diameter: approx.20-
30mm). If the extension is not serious or the area is small, the heating point shall be a little smaller (diameter:
approx.10-15mm). After the heating, beat the heating point immediately. In the beating process, a proper sizing
block is used under the plate. After it is cooled down, beat it lightly with the hammer.
The contraction starts from the highest point to the center, and then to the edge. Heat and flatten the extended
part repeatedly till the plate is flattened fully. If the convex part is too high, compress it to one half of the original
height. After it is cooled down, heat it at the original heating point till the other half of convex part is removed.

Fig. 5-29 Thermal Contraction Method For those parts that are not sure whether they will contract or not, the thermal contraction method shall not
be used to avoiding any side effect. Especially for those thin plates, great attention shall be made to prevent them
from melting down or burning through.
(c) Welding ring
The welding ring method is used to repair the most seriously damaged part of the concave on the plate work
surface. Some rings are welded to connect the rods. (Shown as Fig. 11-30) When the area of the concave is large,
several rings can be welded in a parallel manner, and gets through the rod to make the pulling force act on the plate
surface evenly. The ring can be replaced by the washer. The rod pulls the washer or shaft through a coupling device.
After the concaved plate is flattened by the inertia hammer puller, remove the ring or washer and finish the welding
points.Fig. 5-30 Welding Washer StretchingBody Repair -Repair After Body Damage7-20Washer WasherHeating
Compress
loadCooling
Extend load Plate work
thermal contraction Metal bar thermal
contractionWasherShaft
Shaft Shaft Rod

In addition, there are some other repair methods, such as beating repair (Fig. 5-31), plate reshaping repair
(Fig. 5-32), damaged plate work cutting repair (Fig. 5-33) and welding point cutting repair (Fig. 5-34).(a) Beating RepairFig. 5-31(b) Direct Beating on Deformed Surface(c) Edge & Corner Repair(d) Plane Repair
(a) Beating Modification (b) Check Fine Roughness with FileFig. 5-32Body Repair -Repair After Body Damage7-21Sizing block
Use sizing block
Knife
Knife
Steel plate
Start
Sizing block
FinishBeat
Hammer
Sizing block
Sizing block Hammer
BeatCheck evennessFile
Flexible file

(a) Cutting with Gas Welding
(b) Cutting with SawFig. 5-33Fig. 5-34 (a) Milling Welding Point with Flat Blade Borer
(b) Drill Spot Welding Point with Common Borer(c) Separating Spot Welding Point
(d) Seperating Continuous Welding JointBody Repair -Repair After Body Damage7-22Cutting line
Cutting line
Flat blade borer
Mill welding point
Separate
Brush
Welding point
Determinate position of
welding pointElectronic borer head
Removable piece
Mill welding point
Welding point
Wedge
Grinding wheel
Welding line
Grinding wheel
Welding line

If the collision is not serious and the concave belongs to elastic deformation, the plate can be returned to its
original shape by pressing from the inside surface.
For some concaved parts, they can be repaired in a prizing method. The prizing method is a repair method
that needs not to disassemble the parts. According to the degree of deformation, repair the plate by means of various
clearances and the lever principle. As the prizing method doesn't disassemble the parts, it can keep the original
installation quality and improve the work efficiency.
d. Repair for Unsoldering
The unsoldering is mostly caused by the poor fusion between the welding bar and the metal plate. For the
common unsoldering, weld the metal plate again after remove the welding bar accumulated in the welding line.
For the unsoldering of the spot weld, weld the metal plate near the unsoldered point with a single-side spot welder.The new welding point is about 10-15mm from the original point. Before the spot welding, remove the oil dirt andrust in the welding point to ensure the plates are jointed in a good status. For the unsoldering in some hems, after the two plates are jointed, weld the plates spasmodically on the edgesto make the plates joining together. The welding line at every block is about 30mm long. The line space depends
on the original welding space. Another repair method for the unsoldering is plug welding. This method needs CO2 welding. Bore a dia. 6mmhole on the outside plate, and then join the two plates. Weld the hole with the CO2 welding method. In the welding
process, the welding bare shall point to the inner plate and move in a circular manner, which can make the two plates
welded together. After the welding, finish and paint it.Body Repair -Repair After Body Damage7-23

1. Material of Punch Piece
In order to improve the body's rigidity, high-strength steel plates are used at many key parts on the body. For
the parts under forces, reinforced measures are carried out. (Fig. 5-36)Fig. 5-36 High-strength Steel Panel
1. Engine compartment hood outside panel
2. Left/right fender
3. Left/right mid-door post inside panel
4. Luggage cover outside panel
5. Left/right door outside panel12
3
45Body Repair -Features and Composition of Automobile Body7-24Fig. 5-35 Outline & DimensionsSection 4 Features and Composition of Automobile BodyI. Body Feature The body is an integral structure. Its main structure also is a frame, which can carry all loads. The vehicle is
designed with three compartments and five doors. With the same overall length, the space is utilized fully, which
is helpful to arrangement of passengers. (Fig. 5-35)
14351431
1934.5 1450
4343 848 2502 992

2. Shock Absorption & Noise Isolation
(1) Body structure (Fig. 5-37)
a. Arrange the reinforced bar reasonably to improve the parts' rigidity, reduce the shock and lower the noise.
b. Apply the sealant in the floor seam to improve the floor sealing and reduce the noise in the cabin.Fig. 5-37 Front Wall Panel
1. Front wall bridge reinforced panel
2. Front wall mid-frame panel
3. Front wall lower main panel
4. Heat-isolated pad
Fig. 5-38 (a) Body floor
1. Front mud guard 2. Rear side wall 3. Rear wheel housing 4.Floor sides (2) Deadening
It is an interactive and systemic work to make the body isolate heat, shock and noise. Besides the measures
carried out to improve the body's stiffness and sealing performance, the following measures shall be taken in the
design and manufacture process.
a. Sound isolation material: add sound isolation pad on the front wall and floor.
b. Sound absorption material: add molded carpet on the front floor and rear floor.
3. Sealing
Special consideration has been given to the sealing of the body both in design process and in manufactureprocess. Sealing plays an important role in many aspects, such as dust resistance, water resistance, corrosionresistance, heat resistance, heat preservation, and noise reduce etc. Especially when the body floor and front wall
stay in a tough external condition, the mud, dust, noises (from the tire and engine) and hot air will invade into the
cabin any time.
After the body assembly is welded, sealant will be employed on all joints to prevent the water and steam
penetrating into the metal seam and ensure the quality of subsequent painting.
In addition, a thick layer of impact-proof PVC coat is applied on the base of the body, which has excellentsealing performance. For the sealing to those assemblies, the traditional sealing method is used, such as rubber sealBody Repair -Features and Composition of Automobile Body7-251
123Front4

Body Repair -Features and Composition of Automobile Body7-26Fig. 5-38 (b) Engine Compartmentring, cover, tape and dust shield etc. But these parts are more precise both in design process and in manufacture
process. For those contact seal pieces, the two-way dimension relation is more reliable. For the front windshield
and rear wall glass, a naturally hardened high-strength sealant is used, whose reliability and practicability reach
the state-of-the-art level. (Fig.5-38)Apply sealantApply sealant
Apply sealant

Body Repair -Features and Composition of Automobile Body7-27Fig. 5-38 (c) Body Inside (I)Apply sealant
Apply sealant

7-28Fig. 5-38 (d) Body Inner (II)Apply sealant Body Repair -Features and Composition of Automobile Body