Chevrolet Cruze manuals

Chevrolet Cruze Repair Manual: Overlap/Backing Plate Sectioning (Welding)

Chevrolet Cruze Repair Manual / Body repair / Collision Repair / Overlap/Backing Plate Sectioning (Welding)

Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.

  1. Fit the service panel   to the vehicle to ensure a proper fit.
  2. Measure and mark a line at the sail panel 120 mm (4 3/4 in) from the back glass opening and 70 mm (2 3/4 in) rearward from the rocker panel locating hole edge of the service panel.
  3. Cut along the line to trim the service panel.
  4. Fabricate a 50 mm (2 in) backer plate so that the panel will fit behind the sectioning joint at the sail panel.
  5. Fabricate a 100 mm (4 in) backer plate for the rocker panel.
  6. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.
  7. Bevel the sail panel and service panel edges at the sectioned area to approximately 10 degrees.
  8. Grind a 50 mm (2 in) area of the outer surface on the vehicle to remove any corrosion, E-coat, primers, coatings and galvanizing that may be present.
  9. At the section area on the service panel, grind a 50 mm (2 in) area of the back side to remove any corrosion, E-coat, primers, coatings and galvanizing that may be present.
  10. Drill plug weld holes approximately 13 mm (1/2 in) from the edge of the cuts the sectioning areas of the service panel and the original panel.
  11. Prepare all mating surfaces as necessary.
  12. Apply GM-approved weld-thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
  13. Position and clamp or screw the backer plate with half of the backer plate exposed at the sectioning joint.

Note: Leave a gap of 1 1/2 times the thickness of the metal at the sectioning joint to the original panel.

  1. Position the service panel to overlap the backer plate and 1 1/2 times the thickness up to the original panel.
  2. Check for proper fit and alignment to the vehicle. Clamp the panels together.
  3. Plug weld the backer plate accordingly.
  4. Stitch weld along the entire sectioning joint, make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between them.
  5. Complete the stitch weld.
  6. Clean and prepare all welded surfaces of the entire sectioning joint.

Note: Always follow the system manufacturer's instructions for application, handling, and curing.

  1. Apply a lightweight body filler to the backer plate area.
Collision Repair
Specifications Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements ...

Front Bumper Impact Bar Replacement
Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section. Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section. D ...

Other materials:

Steering Knuckle Replacement
Preliminary Procedure Raise and support the vehicle. Refer to Lifting  and Jacking the Vehicle Remove the wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement. Separate the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie R ...

Prevailing Torque Fasteners
Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners These fasteners accomplish the thread interface by a designed distortion or deformation in the fastene ...

StabiliTrak Syste
The StabiliTrak system assists with directional control of the vehicle in difficult driving conditions. The system is on when the vehicle is started. To turn off both Traction Control and StabiliTrak, press and hold until and illuminate in the instrument cluster. Press again to turn o ...

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