3-16
1997/98 Chevrolet Corvette
Collision Repair
Rail-Underbody Side Assembly
Fig.␣ 3.30 — Plug Weld New Panel to 1” Flange
Created During Removal
— INSTALL OR CONNECT —
1
Stitch weld the tunnel brace to the frame rail,
duplicate factory welds.
2
Attach upper extension panel, and weld
(duplicate factory welds as much as possible).
(
Replace extension panel if heat is required
to straighten.)
3
Trim new lock pillar extension panel to fit
properly. Drill 8mm (5/16 inch) holes for plug
welding along the edge which will overlap
the flange created during removal (Fig.␣ 3.30).
4
Install lock pillar extension in factory location
and plug weld to original extension flange
and to tunnel brace. Stitch weld lower edge
in factory locations to the frame rail.
5
Apply anti-corrosion materials to all inner
surfaces as necessary. Do not combine paint
systems. Refer to paint manufacturer’s
recommendations.
6
After sectioning repairs are completed,
attach panels and components as necessary.
Rear Rail-End Repair
When the rear rail-end is kinked or damaged
beyond repair
rearward of the rear
crossmember. The service part must be cut from
an underbody side rail assembly.
Notice: Use the sleeved butt joint method to
install rear frame ends.
Notice: When determining the area to
perform the sectioning near a riv-nut hole
(within the recommended areas), choose a
location that centers the sleeve through the
hole. This will ensure that riv-nut fasteners
remain straight during installation.
1
Determine sectioning joint location within the
recommended area, (
see Sleeved Butt-Joint
Method Repair Procedures).
2
Perform sleeved butt-joint sectioning as
required. (
Refer to Sleeved Butt-Joint
Sectioning Procedures.)
3
Apply anti-corrosion materials to all inner
surfaces as necessary. Do not combine paint
systems. Refer to paint manufacturer’s
recommendations.
4
After sectioning repairs are completed,
attach panels and components as necessary.
Full Rail Replacement
The left and right frame rails are available as
complete rails for service. This repair procedure
is recommended only in the event the extent of
the damage to the rail exceeds the limits of
partial rail replacement. The complete side rail is
available on a special order basis.
Full rail replacement is accomplished by
combining all of the sectioning location
procedures as necessary to remove and install a
complete underbody side rail. To allow flexibility,
a full rail may be sectioned in any of the
recommended sectioning locations as
determined by the extent of damage to the
vehicle.
When determining frame rail repair location and
method, consider the following:
•
Always straighten and locate rails prior to
attempting any SMC repairs
•
Always inspect SMC and adhesive bonds for
cracks and breaks
•
Always follow recommended repair
procedures for any panels involved in
servicing the frame rail
•
Always follow material and equipment
manufacturers’ recommendations for
materials and equipment used in any repair
procedure
•
Always follow repair procedures and
recommendations to ensure that structural
integrity and safety are restored to the
vehicle