General Procedures - Body Panel Cutting

Special Service Tools / General Equipment

Materials

Repair

NOTICE: Do not perform repairs on the body side sections in the area of the door hinge, seat belt or striker plate attachment points. Welding within 50 mm (1.96 in) of the door hinges or striker plates may compromise structural integrity in a collision.

NOTICE: Separation in the area of the front pillar door hinges, center pillar or curved portion of the side panel is not approved by Ford Motor Company.

1. 1
   Restore the vehicle dimensions to their pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
2. 2
   As a general rule, cut points should be selected to keep the repair area to a minimum.
3. 3
   If necessary, remove the vehicle trim.
4. 4
   Remove only as much of the outer body side as necessary.
   Use common equipment: air saw
   Use common equipment: spherical cutter
   Use common equipment: spot weld drill bit
5. 5
   Cut the replacement panel to fit the repair area and install it.
   Refer to: Joining Methods (501-25 Body Repairs - General Information, General Procedures).
   Use general equipment: Clinching Pliers
   Use major equipment: Resistance Spot Welding Equipment.
   Use general equipment: MIG/MAG Welding Equipment
6. 6
   Rough-coat all seam joints with fiber-based body filler, then finish the seams and welds with standard body filler.
7. 7
   Seal all joints thoroughly to prevent moisture ingress. Water and moisture migrate to horizontal joints, causing corrosion to occur faster in these areas.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
8. 8

   NOTICE: The HVTB (High-Voltage Traction Battery) in an EV (Electric Vehicle), HEV or PHEV may be affected and damaged by excessively high temperatures. The temperature in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work, the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. Temperatures above 60 °C or longer bake times than 45 minutes will require the HVTB to be removed from the vehicle before it is placed in the paint booth.

   NOTICE: If the cure temperature during refinish painting exceeds 60 °C, the charge port indicator ring must be removed.

   Continue the painting process using the Ford-approved paint system and the manufacturer's recommendations.
9. 9
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
10. 10
    If necessary, install the vehicle trim.