Simple deformations are eliminated using a straightening tool and straightening devices, as well as by installing repair pads manufactured at the site of damage. The dimensions of the repair pads must exceed the dimensions of the damaged area by at least 30 mm. Before installing the pads, clean the area with a wire brush down to the metal. Welding is performed with a continuous seam, followed by cleaning the weld and restoring the anti-corrosion coating.
To correct complex deformations, a control and straightening device is used. The body is mounted on the support brackets of the device at the base points and secured on the matching brackets. To align the remaining controlled points with the corresponding brackets, the deformed sections are drawn out and straightened using a hydraulic straightening device.
When repairing damage, remove all easily removable interior trim parts to facilitate measurements, inspection and installation of hydraulic or screw jacks to eliminate distortions and deflections.
The main dimensions for checking the attachment points of the units are shown in Fig. 173.
Fig. 173. Basic dimensions for checking the attachment points of units:
0 - baseline; 1 - Upper radiator mount; 2 - fastening of the steering gear housing and the pendulum arm; 3 - brake and clutch pedal axle; 4 - steering gear center; 5 - center of the rear wheel; 6 - rear suspension shock absorber mount; 7 - rear muffler mount; 8 - Front muffler mount; 9 - Rear suspension crossbar mount; 10 - rear wheel axle; 11 - fastening of the upper longitudinal rods of the rear suspension; 12 - Fastening of the lower longitudinal rods of the rear suspension; 13 - center of the front wheel; 14 - Front suspension crossmember mounting points; 15 - anti-roll bar mount; 16 - lower radiator mount; 17 - car axle; 18 - Upper radiator mount; 19 - rear powertrain mount; 20 - handbrake mount; 21 - fastening of the propeller shaft support;
The diagonal dimensions of the front and rear door openings must correspond to the dimensions shown in Fig. 174.
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The diagonal dimensions of the rear door opening of cars 2102 and 21021 must be equal to (1380±2) mm; dimensions of the opening in height in the middle part (925±2) mm.
Distance between central pillars (without upholstery of pillars) shown in Fig. 175.
The dimensions of the windshield and rear window openings, hood openings and trunk lid openings are shown in Fig. 176 and 177. The difference in the diagonal dimensions of the named openings of one body must not exceed 2 mm.
When repairing the body, it is necessary to restore the external gaps along the contours of the doors, hood and trunk lid (fig. 178 and 179). Unevenness of gaps of no more than 1.5 mm is allowed; the protrusion of the front movable surfaces relative to the fixed ones is no more than 2 mm.
Most often, when repairing a car body, it is necessary to replace the wings, front and rear panels, door sills, and roof panels. The methods for replacing and repairing these parts can be used as a basis for repairing other parts. In this case, it is necessary to know the location of the welds.