Body Frame - General Information (Convertible): Other Volvo C70 I

Galvanized components

Note. Those components which are available as galvanized replacement parts are displayed darker in the following illustrations. Those components not galvanized are displayed lighter.

Volvo uses a large number of body components of single-, double-sided and extra-thickness galvanized steel. This is to achieve the best possible protection against corrosion. Take care not to damage galvanized components when carrying out body repairs, or when grinding or sanding.

On completing work damaged galvanizing must be replaced with single component filler primer.

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Premises

The premises shall be well-adapted for paint work repairs. The maximum level of relative humidity should be 60 - 80%. The temperature inside the premises should be at least 18°C. Remember to keep the premises free from dirt and dust. (The repair shop floor should be painted.)

Work clothes

Volvo supply a wide range of protective equipment e.g. protective masks and spray overalls.

Read more on protective equipment in "Workshop equipment". TP No 375-1

Tools

Use the type of tools indicated in the work instructions.

Methods

The painting methods are based on the paint materials that have achieved the best test results.

Paint materials

Use the materials detailed in the specifications.

Mixing ratios

Follow the mixing ratios detailed in the specifications for each material. Divergence from the mixing ratios can result in reductions to the hardness, weather resistance and resistance to chemicals.

Color comparison

The comparison of color is always necessary at each painting, as most paints alter their shade through aging, the affect of weather etc. Differences in shade can even depend on varied thickness, changes from heat-painting, change of paint supplier etc. Differences of shade with metallic paint often result from variations in spraying technique, coat thickness and paint runs.

Note. Always check the production number when using large amounts of paint. Otherwise mix the whole amount in advance whereby the risk of differences in shade will be reduced.

Drying

The surface temperature stated in the repair instructions should always be achieved in order to obtain the best result.

The car should be kept indoors (20°C) for at least 12 hours after painting. This is to avoid damage to the paint work from moisture.

Sand paper grades

The grade of sand paper in the instructions is given according to the FEPA numbering system (FEPA = Federation of European Abrasives Manufacturers).

The numbering according to grain size is not standardized. Consequently there are differences within the US standard between silicon carbide and aluminum oxide and between the US standard and the European FEPA-Micro terms. Sometimes a P is placed before the grain size number when using the FEPA terms in order to indicate the difference better.

Anti-corrosive treatment

All bodywork surfaces which have been repaired shall be given anti-corrosive treatment after painting in accordance with Volvo's directions.

See SHB Pt 8 (81, 84)

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Coat thickness meter

The thickness of the coat is important for a good result. A mu-meter is required to measure the thickness. The meter must be calibrated before measuring the thickness.

Working with chemical products

The use of chemical products is mentioned in several places in this manual. A number of these products contain solvents and other substances which can involve a large risk to health, which means that special caution should be taken when handling these products.

As a professional user of a chemical product, you should always request a product information leaflet from the supplier. This describes the degree of hazard involved, the protective measures to be taken and the measures to be implemented in the event of an accident. The supplier is legally responsible for supplying the product information leaflet to professional users.

According to the law, all dangerous chemicals should carry a hazard warning label. Always remember to read it and any other instructions to be found on the packaging before beginning work with a chemical product.

There are a number of general points below concerning substances which may be contained in the products mentioned in the manual.

Note. The points below does not replace the supplier's product information leaflet for a specific product. Since a product which fulfills a certain function can consist of different substances depending on the product, no general remarks e.g. "Plastic putty" or "Dilution", can be made regarding health hazards.

Important to consider.

Hazardous substances can be released during the sanding or welding of painted surfaces even when the surface is dry and the coat being treated has hardened. The composition of sanding dust/welding smoke depends on how the surface is treated. In certain cases the dust can contain, for example, lead chromates and other pigments containing heavy metal which if repeatedly inhaled over a long period can involve a certain cancer risk. Free isocyanides can also occur (health risks, see below). Therefore use breathing protection when working on pre-treated/painted surfaces if the surface becomes very warm during work on it.

Comprehensive legislation exists for how paint spraying and associated work should be carried out, covering among other things requirements for equipping the premises, the ventilation required, etc.

Residues and other waste products from the repair work is classified as environmentally hazardous waste and should be dealt with by the person(s) who collect such waste products at the place of work.

General remarks on substances which may be contained in the products mentioned in the manual (always refer though to the suppliers' product information leaflet)

Organic solvents

Are contained in for example paints, primers, fillers, anti-corrosive agents etc. Organic solvents when inhaled can cause headaches, dizziness and nausea. In the case of repeated inhalation of high concentrations over a longer period, the solvents can affect the nervous system and give rise to chronic damage such as memory loss and concentration difficulties. Some solvents are absorbed through the skin and so can have similar effects as when inhaled. Organic solvents in general, dry out the skin and can cause skin problems because of their degreasing effect.

Pigment

Pigments are the components in the paint that give it its color. Some pigments contain lead and other heavy metals which involve both a health and an environmental risk. Products containing such pigments should not be used if other less hazardous alternatives are available. Certain products from Volvo Car Corporation. After sales do not normally contain this type of pigment.

Isocyanides

Are often contained in the hardener of a two-component paint. Isocyanides which are spread as particles or in gas form by, for example, spraying, are aggressive when even low amounts are inhaled and can cause asthma. When handled in this way, "fresh-air masks" should always be used. Certain isocyanides can also cause allergies when coming into contact with skin.

Styrene

Styrene is a solvent which is often contained in various types of plastic base filler. High levels of styrene can irritate the breathing passages and the eye membranes, and when inhaled, the nervous system is also affected causing symptoms such as headaches, dizziness and nausea. Repeated inhalation of high levels over a longer period can cause solvent damage and have some affect on the blood.

Organic peroxides

Are often contained in plastic base filler. Organic peroxides are extremely irritating to the skin, mucous membranes and the eyes. Some types can cause corrosive damage. Repeated skin contact with organic peroxides involves some risk of allergic contact eczema. Organic peroxides oxidize which means that they emit acid and may cause fires without the supply of oxygen. Therefore store organic peroxides away from inflammable materials.

Epoxy

Some paints contain low-molecular epoxy resin which can give rise to skin irritations and allergic contact eczema. High-molecular epoxy resin can also involve some allergy risk for persons who are already sensitized.

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The Service Manual demonstrates methods which will result in the highest possible quality body repairs.

Volvo has developed its own bodywork repair methods.

For further details see Workshop guide manuals 4 and 5.

We have selected a number of repair methods which illustrate the basic principles of body repair.

Use the correct tools.

Do not grind surface coating, electro-deposition (ED), phosphate coating or filler and welding primer unless it is necessary.

Always finish work by rust proofing

Take care with soundproofing and insulation. Reinstall or replace after the repair is complete.

Note. Always use genuine Volvo parts and consumables

Bodywork dimensions

1. Ensure that bodywork dimensions are not changed when the car is raised.

Using an alignment bench

1. Cars must be straightened in an alignment bench if structural components are damaged. See relevant supplier instruction manual for alignment bench operation.

Filler and sealant

Plastic filler and solder can be used to even out edges and irregularities.

Note. Max 1 mm plastic. Max 4 mm solder

Note. Follow the instructions for galvanized body components.

Clean with acetone before sealing

Apply filler primer to all areas which have been ground and where sealant is to be used

Allow the primer to cure for 15 minutes before sealing

Grind the area and fill the joins

This helps to protect the join against corrosion.

The sealant can be painted after approximately 2 hours .

Replacement doors and hatches must be sealed before painting.

Treat components with rustproofing agent after spraying

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Only grind down old welds and metal residue.

Remove caulk residues etc. with Scotch-Brite or similar.

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Align the edges of all panels and mating surfaces with a hammer and counter-hold

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Cut the new replacement part if it is to be butted into place.

If a whole replacement panel is being used, check to ensure that it fits.

If possible cut the replacement part and the body section at the same time.

Position joints edge to edge.

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Secure component with welding grips.

1. Tack weld the section with a few spot welds. Carefully follow the repair instructions.

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Complete the welding.

Note. Always use protective gloves and welding visor.

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Punch replacement part for plug welding

1. Select size of hole according to the thickness of the metal
2. 8 mm for thicknesses less than 2.5 mm
3. 10 mm or more if thickness is more than 2.5 mm

Distance between the holes

Distance between the holes

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Apply welding primer to all internal flanges. Allow to dry for 15 minutes .

If there is any grinding damage outside the welds, apply filler primer. Allow to dry for 15 minutes .

Make sure that the spot welds take properly on both panels .

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Grind plug welds with a grinding disc

Resistance spot welding

Resistance spot welding can be used to advantage if the capacity of the welding equipment is matched to panel thickness. When carrying out resistance spot welding grind down to bare metal.

Clean the surfaces with Scotch-Brite or similar. This protects the zinc coating and phosphate coating on the metal. This retains corrosion protection and does not affect the welding process. The distance between the welds should be the same as for the original.

Test weld some sample pieces and check weld quality (twist apart).

1. HSS components require a smaller gap between welds

Prior to welding

1. Check the area where the new sections are to be installed. If there is grinding damage, areas of bare metal etc. outside the ground welding edges, protect the area with filler primer. Allow the primer to cure for approximately 15 minutes before welding.

Apply welding primer to both inner weld surfaces. Allow to dry for 15 minutes .

Rough aligning/rough cutting

Make sure that all indirect damage has been repaired before removing the parts to be replaced

Use hydraulic equipment etc. for rough alignment

Use a cutting disc or compass saw if the distance to the components being retained is at least 50 mm

Treat damage to panels with a layer of filler primer

Coat inner weld surfaces with welding primer. Allow to dry for approximately 15 minutes .

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Use a drill (D = approx. 8mm) and a grinder with cutting disk to separate components. Use a chisel to remove damaged components.

Remove solder, filler, sealant and wear protection from hidden joins before separating welds.

Welding, general

Volvo bodies are made to the highest standards. So all bodywork repairs should follow the same principle. Use the correct tools. Protect surface coatings, electro-plating (ED), phosphate coating, sealant and welding primer.

Note. Always use genuine Volvo replacement parts for repair.

Resistance spot welding and bonding are primarily used during bodywork construction.

Instructions are based on MAG plug welding (Metal Active Gas) because this is the most commonly used welding method in workshops. When carried out correctly MAG welding meets both strength and appearance requirements.

Gas welding must not be used on Volvo bodywork

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There are a number of different welding methods which can be used and are indicated by the following symbols. If only one method is indicated, only that method can be used.

The exception is spot welding which can be replaced with plug welding.

1 = Spot welding. 2 = Plug welding. 3 = Seam welding.

4 = Step welding. 5 = Tack welding. 6 = adhesive.

HSS components require a smaller gap between welds.

Test weld some sample pieces and check weld quality (twist apart).

Prior to welding

1. Exposing

Plan the work. Do not remove more components than necessary. Remember they must all be reinstalled.

Check cable harnesses.