Acura RL (1996-2004 year). Instruction — page 11

• Remove the burrs from the drilled sections with a

disc sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Center punch around the spot weld imprints on the front

side frame and front side extension from inside the

passenger compartment.

• Drill holes in the spot welded area with a 5 mm (0.2 in)

drill.

NOTE: Drill holes completely through the parts since the

replacement front side frame and front side extension will be

welded by MIG welding.

• Remove the MIG welds of the front side frame-and-lower

dashboard with a disc sander.

NOTE: When drilling holes ( , and ) be careful not

to drill down to the inside sill.

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Front Side Frame

Replacement (cont’d)

6. Mold the related parts.

• Reshape the front wheelhouse and damper housing

lower dashboard-to-front floor joint using a hammer

and dolly.

• Fill all drilled holes by MIG or gas welding.

NOTE: Use of a positioning jig is recommended (see

page

1-7

).

• Clamp the front bulkhead and front wheelhouse/

damper housing with squill vises and vise-grips.

• Measure the front compartment diagonally.

• Spot weld several points in the clamped sections,

and temporarily attach the front side frame.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Check the body dimensions (see

section 6

).

8. Perform the main welding.

• Make 20% to 30% more spot welds than there were

holes drilled.

• Weld as much as possible with the jig still mounted.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Weld the front side frame, wheelhouse, damper

housing and bulkhead.

7. Set the new front side frame.

• Remove the undercoat from the both sides of the

welding section, and expose the steel plate using a

disc sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

NOTE: Apply the spot sealer to the welding surface

when spot welding.

• Tighten the front side frame against the front floor

and side sill using vise-grips or pliers.

• Place a jack under the front side frame end and

support it, and measure the positions for temporary

attachment.

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• and make 5 mm (0.2 in) holes in the MIG weld

holes with the front side extension, and plug weld the

inside sill, floor frame and side sill extension with a MIG

welder.

9. Finish the welds.

Use a hammer and dolly to even out the damper housing,

wheelhouse, lower dashboard, front bulkhead and side

sill flanges for a close fit with the surface of the front side

frame.

10. Apply the sealer (see

section 5

).

Apply sealer to the mating surfaces of the lower dash-

board, etc.

11. Apply the paint.

See Paint Repair section.

• Ventilate when spraying paint. Most paint

contains substances that are harmful if inhaled

or swallowed. Read the paint label before

opening the paint container.

• Avoid contact with skin. Wear an approved

respirator, gloves, eye protection and appropriate

clothing when painting.

• Paint is flammable. Store it in a safe place, and

keep it away from sparks, flames or cigarettes.

12. Apply the undercoat.

Undercoat the front floor, and apply anti-rust agent to

the inside of the welding section of the side sill, front side
frame, etc (see

section 7

).

13. Install the related parts.

Install in the reverse order in which they were removed.

14. Inspect, check and adjust.

• Measure the front wheel alignment.

• Inspect the brake system.

• Adjust the headlight aim.

• From the passenger compartment side, plug weld

the holed areas of the lower dashboard and front

floor with a MIG welder.

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Front Side Extension

Description

The front side extension connect the front side frames to the body and are vital to the rigidity of the entire body frame. Pay particular

attention when welding the front side extension from beneath the front floor and side sill.

Mass Production Body Welding Diagram

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