Soldering Steel Components (Cooper, Cooper S, John Cooper Works)

Safety regulations (See INFORMATION ON HAZARDS (COOPER, COOPER S, JOHN COOPER WORKS)  And SAFETY AT WORK (COOPER, COOPER S, JOHN COOPER WORKS) ).

Handling electrical system, electronics, airbags and restraint systems (See HANDLING AIRBAGS AND RESTRAINT SYSTEMS (COOPER, COOPER S, JOHN COOPER WORKS)  And HANDLING ELECTRICAL SYSTEM AND ELECTRONICS (COOPER, COOPER S, JOHN COOPER WORKS) ).

1. General information 
   • For repair cases the following procedure will implemented:
     • Autogenous brazing solder
   • The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams used in standard production are replaced during repairs by MAG weld seams.
   • Brazed areas from vehicle production are bonded following the same procedure.
2. Work materials 
   • Cable hose assembly and flashlight (oxyacetylene blowtorch)
   • Brazing solder
   • Gas bottles (oxygen and acetylene)
   • Welding goggles
3. Preparation 
   • Remove the paint and zinc layer in an area of approx. 30 mm around the seam to be soldered.
4. Implementation 
   • Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use heat protecting paste.
5. Subsequent treatment of brazed connections: 
   • Remove burnt residual zinc completely. Align and grind visible connection areas.
   • Remove burnt paint with a stainless steel wire brush.
6. Notes on melting/tinning: 

   Only applicable within the European Union!

   Due to the European End-of-life Vehicles Act, no leaded tin may be used on vehicles brought into circulation after 01.07.2003!

   Even out unevenness smaller than 2 mm with filler according to painting handbook.

   Only perform in visible areas of the outer skin and on the carrier support.

   All areas which have covers on the vehicle are not to be processed.