SKODA OCTAVIA 1997 1.G / (1U) Body Repairs Owner's Manual

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Edition 08.96


Spot welding (RP) galvanised panels Pay attention to the following points when resis- tance spot welding galvanised panels:
Welding transformerIncrease the welding current by 10% up to a max. of 30%.
If the welding transformer is fitted with a „welding time control“ it is better to extend the welding time.
Extending welding time related to panel thick- ness (reference values):
0.7 mm - min. 7 periods
0.8 mm - min. 9 periods
1.0 mm - min. 11 periods
The correct welding time has been selected ifthe weld spots can be placed without any
splatter. Electrode holder Use hard copper electrodes (copper-chro- me-zirconium alloy) with resistance to high temperatures (>400 °C).
Clean hard copper electrodes frequently or rework side of contact surface diameter to
∅4 mm.
Increase electrode contact force.
Pull-out test The best welding results can be determined by welding specimen sheets followed by a pull-out test.
This is done by unrolling or tearing off the narrow welded specimen strip from the second strip of sheet with a force acting vertically to the surface of the sheet. If the weld spot has been properly carried out, it will not tear in the contact plane when this is done, but will be pulled out.

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Edition 08.96

Removing underbody sealant and weld seams
Underbody sealant and weld seams must be removed with a wire brush wheel clamped in the angle grinder or in the compressed air
straight grinder.
Note
It is essential to wear eye protection and pro-tective gloves. The pieces of wire which may fly off are very sharp.
A further possibility is to heat the underbody sea- lant or the weld seams with a hot air fan (max. 420 °C) and to remove the softened underbody
sealant or the weld seams with the scraper. This procedure is particularly recommended for poorly accessible areas of work.
Important!
The vapours produced are toxic and should be ex-tracted using suitable extraction equipment, e.g.V.A.G 1586.
Remove paint and primer with paint remover.
Body sections and part sections
„Sections“ refer to sections of single parts which are supplied from the Parts Depot already cut to shape. „Part sections“, in contrast, have to be cut to shape in the body shop from replacement parts.

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Edition 08.96




 
Original joint
„Original joint“ refers to the weld joint which was made during the production of the vehicle. Such weld joints should be re-created to the ma- ximum extent possible during body repairwork. An important point to note is that the number of weld spots made when carrying out body repairs should not be less than the number in standard production but, for safety reasons, should rather be more if space conditions permit.
Methods and procedures differing from the ori- ginal joint are described in this Body Repairs
Workshop Manual.

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  Edition 08.96

Explanation of symbols Explanation of symbols for welding work

Spot weld seam (single row) Spot weld seam (double row)
Spot weld seam (double row offset) Shielded arc plug weld
Shielded arc stepped weld (has to be ground
off, if necessary, to match shape of body) Shielded arc continuous weld (has to be ground
off, if necessary, to match the shape of body) Shielded arc continuous weld, staggered (has
to be ground off, if necessary, to match the sha- pe of body) Brazing
Notes:
Shielded arc plug weld: (∅ 7 mm holes, spa-
ced 20-30 mm apart, are made in one of the
sheets to be connected in the area of connec-tion points, into which a good shielded arc
weld spot is placed.
Shielded arc continuous weld: the weld seam is carried out without any interruption if possi-
ble.
Shielded arc stepped weld: the weld seamis composed of a large number of individual
weld spots placed one after the other. Theadvantage of this method is the lower tem-perature introduced into the sheet compared
to shielded arc continuous welding
Shielded arc continuous weld (interrupted):the weld seam consists of shielded arc con-tinuous seams about 20 mm long, placed oneafter the other and separated by equally long
intermediate spaces.

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Edition 08.96




 
Explanation of symbols for methods

Stepping with stepping pliers in order to carry
out an overlap weld.
Plugging with plugging pliers in order to carry out subsequent shielded arc plug welding. Drilling in order to carry out subsequent shielded arc plug welding or to drill out weld spots (original joint).
Grinding with straight grinder in order to remove the material applied to the weld seam.

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  Edition 08.96

Cavity protection
Bonding Fine sealing

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Edition 02.03
S00.5119.56.20Tools
Tools required

Right angle grinder (e.g. EBU 18-E2)
One-hand right angle grinder (e.g. WS-125) and wire brush
Welding point loosening tool (e.g. Variodrill
V.A.G 1731)
Sheet metal and body saw (e.g. V.A.G 1523)
Welding fume extraction (e.g. V.A.G 1586 A)
Body tool carrier (e.g. V.A.G 1439)
Door tension adjuster (e.g. V.A.G 1438)
Underbody sealant gun (e.g. V.A.G 1379)
Burring pliers
- To burr panels e.g. for overlapping seams
Punch pliers (e.g. V.A.G 1329)
- To punch holes in panels (e.g. for shielded arc plug weld)
Panel nibbler
- To cut out panels without warpage or burr- ing (e.g. when subsequently fitting a glasssun roof)
Pneumatic gun (e.g. V.A.G 1761/1)
- Pneumatic gun to produce seals and apply underbody protection having the same ap- pearance as the original factory finish.
- Moreover all 310 ml cartridges can be used in this gun
Pneumatic gun for 2k window glue (e.g. VAS 5237)
Pressure beaker gun for hollow space seal-
ing (e.g. V.A.G 1538)
Inert gas shielded welding tool
Spot welding and sheet panel machining tool
(e.g. V.A.G 1713)
Rig alignment bench Celette M85 with align-
ing device and straightening angle set VAS 5020/1
Basic equipment (e.g. V.A.G 1366/3)
Rod grinder with wire brush
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1 7 ------------

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  Edition 08.96

Corrosion protection measures Corrosion protection
The body is manufactured from sheets galvani- sed on both sides. It is essential to re-create the standard corrosion protection after carrying out body repairs using the material specified by the manufacturer as this is a precondition for ensuring the absence of corrosion.
Long-life body protection
- Prime bright metal sheet parts immediately
after carrying out repairs (corrosion protecti-on primer ALN 002 003 10 or ALK 007 003 10).
- Spray outer skin sheets from the inside with top coat before welding in place.
- Always apply zinc spray (D 007 500 04) to both sides of spot welded flanges.
Note
Areas which are subsequently shielded arc-wel-ded, must not be pre-treated with zinc spray.
- Prime weld seam areas from the inside and outside with corrosion protection primer ALN002 003 04 before sealing.
- Apply sealing compound only to primed sheet metal parts and allow to harden sufficiently before further treatment with paint.
- Seal sheet metal overlaps, sheet edges, butt joint, weld seams etc. completely with sealing compound.
- Re-create the underbody sealant using long- life underbody sealant material.
- Protect all the cavities in the area of the repair after applying the top coat.
- After the cavity protection material has dried, open the water drains.

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Edition 08.96




 
Separating galvanised body parts
Preparatory work
- Remove underbody sealant and weld seams
Basic information, page 00-12.
Cutting operation
- Do not use cutting operations which involve heat, e.g. cutting torch.
- It is best to use mechanical cutting methods, e.g. weld spot milling, body saw, to avoid any damage to the zinc layer in the area of the cut.
Welding galvanised body sheets Basic information, page 00-10.

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