ROOF, BACK PANEL AND REAR FLOOR PANEL 5–9
4. Peel off the undercoat and sealer.
• Heat the undercoat and sealer at the welding
areas of the rear side outer panel and extension
rear floor with a gas torch and peel off the under-
coat and sealer with a steel spatula.
5. Mold damaged related parts.
• Use a hammer and dolly to mold damaged areas
of the rear side outer and extension rear floor
panel.
• Even out the welding flanges with a hammer and
dolly.
• Fill any holes drilled by welding.
6. Set the new rear panel.
• Grind both sides of the welding section of the rear
panel with a sander to remove the paint and ex-
pose the steel plate.
CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
• Clamp both the right and left sides with the vise
grips as shown.
• Weld the clamped sections for temporary instal-
lation.
CAUTION: To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
7. Measure and check.
• Measure the trunk compartment diagonally to
check it for twisting or bending and its correct
position with the rear bumper installed.
• Temporarily assemble the rear combination lamps
and trunk, then check the clearances and level
differences.
8. Perform the main welding.
• Make MIG or gas welds at the butt joints.
• Spot weld the back panel as shown.
CAUTION: To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
• Perform a trial welding first, and check the weld-
ing condition.
• Increase the number of spot by 20% for areas to
be spot welded.
Fig. 12
Fig. 13
9. Finish the welding areas.
• Level the gas or MIG welded areas with disc
sander, then even out high areas with a hammer
being careful not to deform them.
• Use a hammer and dolly to even out the rear side
outer and extension rear floor panel flanges for a
close fit with the surface of the rear panel.
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