Geely CK Series 2007 Workshop Manual page 381

2. Repair Of Outer Plate
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Repair of crackle
The crackle on the metal outer plate can be repaired by CO2 gas Protecting welding. When welded, the
two sides of the metal plate should be aligned, and then spot-weld on the outside of the outer plate. If the
crackle length is less than 50mm, it should be welded from the crackle end, and along the run of the
crackle and the outside edge. If the crackle length is very long, it should be spot-welded in some intervals,
and then weld the crackle in several sections. So, it can prevent the crackle metal from being over-burnt
and warping because of an extremely high temperature.
If the crackle appears on the place that is greatly loaded and it is very convenient to weld, 2-step welding
can be adopted, that is, After spot-welding on the outside, then you can first weld on the inside of the
crackle. After that, a welding seam is then applied on the outside in the same run.
After the welding finishes, put a backing block under the crackle, and then use a hammer to gently knock
on the outside of the crackle to remove the remaining welding stress. Finally, trim the appearance of the
crackle to make it smooth and convenient to apply paint.
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Repair of partial damage of the outer plate
When the outer plate has partial rust or serious damage and even cannot be repaired, it can be mended by
cutting off the damage or pasting a new one on it.
How to cut off the damage:
a. Confirm the area that needs cutting;
b. Cut a paper example;
c. Cut the metal plate according to the paper example;
d. Paste the metal piece cut onto the surface of the area that needs cutting off;
e. Use a draw needle tip to make an outline along the sides of the metal piece. And cut off the
damaged or rusted area along the outline;
f. Use a wooden hammer or a backing block to smooth the cut, and use a file to file the burr, to assure
that the cut is parallel with both sides of the substitute piece and the clearance should be no more
than 1mm;
g. Substitute the damaged area with the piece. Use pliers to hold it and spot-weld the joint in an
interval of 50mm for fixation;
h. Weld in sections. First weld the central part and then the left and right in turn, to avoid deformation;
i. Use a hammer or block to knock on the seam to remove the remaining stress. And use a file or
hand grindstone to grind the seam to make it smooth to the plates around. Finally, paint the substitute
piece.
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Repair of uneven damage of the outer plate caused by crash
When the outer plate is crashed, a concave pit appears on it. The repair should be taken from the point C
(Figure 5-17). Put the block on the top of the protrusion area, use a hammer to knock it and correspondingly
change the position of the block. After the protrusion area is knocked down to the level, most of concave
in B area will spring back. It is already very much like the former outline of the plate. As to some little
remaining depressions, use a block with a same radian with the plate and use a hand to press the block
upwards. Knock the top point of the concave with a hammer (Figure 5-19).
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