Panel Alignment

Panel Alignment

Offer up panel to body.
Adjust panel for alignment.
Clamp where possible using mole grips.
Screw using P.K. screws where clamps inhibit closure of hanging panels.
Tack weld using M.I.G. or spot weld (resistance welding).
Inspect for correct alignment to associated panels.

Check and compare alignment and gaps to the criteria as follows:
Dimensions and gaps must be strictly adhered to in order to preserve the integrity of the original design tolerances when undertaking a repair of any nature.
Wherever a panel, closure or component is renewed, refitted or reset, the factory specifications for clearance (gap) and alignment (profile) MUST be attained.
There is no distinction between the importance of visual and operational characteristics; all conditions must be satisfied so the vehicle looks and operates to the satisfaction of both design intent and the customer.

Criteria-Clearances.







- Gaps should be uniform around body panel contours.
- Gaps must be parallel to within 1 mm in a 400 mm linear measurement.
- Panels which are centered between 2 (two) adjacent panels must have equal gaps either side; there are exceptions to this, please refer to the appropriate specification.
- Gaps between adjacent panels or components must not expose harnesses, labels, brackets or visually poor joint or assembly conditions

Particular areas of concern:
- Fuel filler flap.
- Trunk lid to fenders and saddle.
- Hood to fenders, grille and headlamps.
- Sliding roof panel to the main roof panel.
- Door gaps at fender, B/C pillar, roof drip rail and rocker panel.
- Bumper cover to fender and cross vehicle assemblies

Criteria-Alignment
- Panels must be correctly 'profiled' to maintain cosmetic appearance, pressure on seals and control wind noise.

Particular areas of concern:
- Hood to fender.
- Trunk lid to fender and saddle.
- Door to aperture. Door to fender and adjacent door.
- The relationship of the sliding roof panel leading and trailing edges to the main roof panel.

Criteria-Exterior Fitments
- Bezels, trims and lamps must be centered within apertures and have equal clearances with adjacent panels.

Particular areas of concern:
- Headlamp to hood, fender and trim panel.
- Exhaust tailpipe trim to bumper cover cut-out.
- Rear lamp assembly to trunk lid, fender and bumper cover trim.
- Feature lines fender to door and door to door (this includes body side moldings).

Note: Structural panels carrying critical suspension assemblies must be aligned using jig fixtures to ensure dimensional accuracy.