Iveco DAILY M.Y. 2012, Body Builder Instructions

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CHASSIS MODIFICATIONS
2-11
D
AILY
Printed 603.95.241 Base — 02/2012
Drills on the chassis
Welding procedures
a) Carefully remove any paint and traces of oxidation from the parts of the chassis involved with the welding as well as those that
must be covered with reinforcements.
b) Cut the side members with a slanted or vertical cut. The side members must not be cut at the points where the chassis contour
and width changes or where stress is greater (e.g. spring mounts). The separation line must not involve the holes on the side
member (see Figure 2.4).
YES
YES
91446
Figure 2.4
YES
YES
YES
YES
NO
NO
c) Make a 60
°
V shaped chamfer on the parts to join on the inner side of the side member along the entire length of the area
to be welded (see Figure 2.5).
91447
Figure 2.5
d) Perform arc welding with several passes using carefully dried basic electrodes.
Avoid current overload; the weld must be free from marginal cuts and waste material.
e) Repeat in the other direction and make the weld as specified in point d).
f) Allow the side members to cool slowly and uniformly. They must not be cooled using an air jet, water or another method.
g) Grind off the excess material.
h) Apply angular steel reinforcements on the inside, with the same specifications as the steel used in the chassis. The approximate
minimum dimensions are specified in Figure 2.3.
The reinforcements may only be secured on the vertical rib of the side member and may be implemented with welding beads,
false spots, screws or rivets (also Huck rivets).
The welding bead section and length, as well as the number and arrangement of false spots, screws or rivets, must be suitable
to transmit the bending and cutting moments of the section.
i) When the work is completed, protect with rust proofing (see paragraph 2.3.2).