Steps to put sportscars back on the road and track

Aug. 1, 2019
With so many sportscars utilizing long, sloping front-ends engineered with a host of lightweight materials and bonds to compensate for heavy engines and suspensions, these vehicles can offer significant repair challenges.

Pity the poor sportscar.

That’s the shared opinion of many in the automotive sales and repair industries, which shouldn’t come as much of a surprise to anyone familiar with this vehicle segment. Even with respectable sales, these hot-running coupes always seem to be on the chopping blocks of auto manufacturers looking to shelve these vehicles to concentrate on far more popular SUVs, trucks and crossovers. For their part, repairers have grown used to seeing their mangled shapes towed to their doors, often because owners are eager to test their limits or too willing to put safety in the back seat when an aggressive roadway comes calling.

More than a few shop owners refer to sportscars as the kings of front-end damage. “We don’t see a lot of Mustangs, Camaros or anything like that with rear impact damage,” says Joe DeClaro, owner of Atlantic Collision and Restoration in Jacksonville, Fla. “You see some side impacts, but most of the time it’s severe front-end damage going right up to the driver’s compartment.”

(Photo courtesy of GM media) The long, sloping front-ends of sportscars might be beautiful, but they create a number of collision repair issues.

With so many sportscars utilizing long, sloping front-ends engineered with a host of lightweight materials and bonds to compensate for heavy engines and suspensions, these vehicles can offer significant repair challenges. The final weeks of Summer are a great time to brush up on your knowledge of front-end work as sportscar owners take advantage of their waning driving season (especially in northern parts of the country).

Refer to the following repair steps supplied by General Motors for the 2019 Chevrolet Camaro. As you work your way through them, note the level of detail in this work and the need to strictly adhere to OEM instructions to return a sportscar to form.  

Front End Upper Tie Bar Replacement

Removal Procedure

Warning: Before starting, refer to the following GM documents.

  • Approved Equipment for Collision Repair Warning
  • Glass and Sheet Metal Handling Warning
  1. Disable the supplemental inflatable restraint (SIR) system. Refer to GM’s SIR Disabling and Enabling instructions.
  2. Disconnect the negative battery cable. Refer to GM’s Battery Negative Cable Disconnection and Connection instructions.
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to GM’s Dimensions – Body instructions.
  5. Locate and remove upper tie bar rear fasteners.
  6. Locate and remove upper tie bar lower fasteners.
  7. Remove the damaged tie bar assembly.

Installation Procedure

Note: Verify that all mounting points for the upper tie bar are within dimensional specifications prior to installing the replacement tie bar.

  1. Remove the rear attachment brackets that are bolted to the tie bar ends on the replacement part.
  2. Install the replacement tie bar upper fasteners to the vehicle.
  3. Install lower attachment bolts.
  4. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to GM’s Anti-Corrosion Treatment and Repair instructions.
  5. Paint the repair area. Refer to GM’s Basecoat/Clearcoat Paint Systems instructions.
  6. Install all related panels and components.
  7. Connect the negative battery cable. Refer to GM’s Battery Negative Cable Disconnection and Connection instructions.
  8. Enable the SIR system. Refer to GM’s SIR Disabling and Enabling instructions.

Windshield Frame Header Front Panel Replacement

Removal Procedure

Warning: Before beginning, refer to the following GM instructions:

  • Approved Equipment for Collision Repair Warning
  • Foam Sound Deadeners Warning instructions
  • Battery Disconnect Warning.
  • Glass and Sheet Metal Handling Warning.
  1. Disable the SIR system and then disconnect the negative battery cable. See GM’s SIR Disabling and Enabling instructions.
  2. Remove windshield and all related panels and components.
  3. Visually inspect the damage. Repair as much of the damage as possible. See GM’s Dimensions – Body instructions.
  4. Remove the sealers and anti-corrosion materials from the repair area as necessary. See GM’s Anti-Corrosion Treatment and Repair instructions.

Note: Record the number and location of the original welds for installation of the service assembly.

  1. Remove factory welds as required from the windshield frame header front panel.
  2. Heat the outer edges of the windshield frame header front panel to release the factory impact resistant adhesive.
  3. Remove the damaged windshield frame header front panel.
(Photo courtesy of GM media) OEMs have gotten much better engineering sportscars with lighter, powerful engines. Still, manufacturers continually offset their weight (along with special suspensions) with a variety of weight-reducing materials and bonds.

Installation Procedure

  1. Prepare all mating surfaces as necessary using 80 grit abrasive.
  2. Clean and prepare the attaching surfaces for welding/bonding.
  3. Position the windshield frame header front panel on the vehicle.

Verify the fit of the windshield frame header front panel and apply impact resistant adhesive to all mating surfaces where factory impact resistant adhesive was applied. See GM’s Metal Panel Bonding instructions.

  1. Weld/weld-bond the windshield frame header front panel accordingly at the original weld locations.
  2. Clean and prepare all welded surfaces.
  3. Apply the sealers and anti-corrosion materials to the repair area as necessary. See GM’s Anti-Corrosion Treatment and Repair instructions.
  4. Paint the repaired area. See GM’s Basecoat/Clearcoat Paint Systems instructions.
  5. Install the windshield and all related panels and components.
  6. Enable the SIR system and then connect the negative battery cable. See GM’s SIR Disabling and Enabling instructions.

Front Wheelhouse Panel Replacement (Complete)

Removal Procedure

Warning: Before beginning, refer to the following GM instructions.

  • Approved Equipment for Collision Repair Warning
  • Foam Sound Deadeners Warning
  • Battery Disconnect Warning.

Note: The front wheelhouse panel is cast aluminum and is rivet-bonded to the front lower frame rail (Ultra High Strength Steel) and hinge pillar upper extensions (Dual Phase Steel). The front wheelhouse is serviced as a complete assembly that includes the hinge pillar upper extension, which is rivet-bonded to the front wheelhouse panel.

Note: This procedure describes how to replace the complete front wheelhouse assembly, using recommended adhesive and rivets to attach the assembly to the front lower frame rail. The assembly requires welding at the cowl on the upper hinge pillar extension.

Note: Partial replacement of the front wheelhouse assembly can be done by replacing only the front wheelhouse panel (cast aluminum). The front wheelhouse panel will need to be separated from the complete wheelhouse service assembly and replaced using adhesive and rivets.

  1. Disable the SIR system and then disconnect the negative battery cable. Refer to GM’s SIR Disabling and Enabling instructions.
  2. Remove all related panels and components.

Note: Inspect the front of the cowl for damage. If the metal surface is damaged, the cowl panel must be repaired to restore the structural integrity of the vehicle.

  1. Repair as much of the damage as possible. Refer to GM’s Dimensions - Body instructions.
  2. Remove the Sealers and anti-corrosion materials from the repair area, as necessary. Refer to GM’s Anti-Corrosion Treatment and Repair instructions.

Note: Record the number and location of welds for installation of the service assembly.

  1. Remove all necessary factory welds. Next, remove the front upper outer rail and the front tie bar attachment bracket to access rivets and hinge pillar upper extension welds.

Note: Record the number and location of welds for installation of the service assembly.

  1. Remove all necessary factory welds for the upper outer rail reinforcement bracket and then remove the upper outer rail reinforcement bracket. Next, remove the welds from the hinge pillar upper extensions from the cowl area.

Note: Record the number and location of the rivets for installation of the service assembly.

Note: The rivets can be removed using a chisel and hammer to remove the head of the rivet and then driving out the remainder of the rivet with a punch and hammer, or drilled out with a suitable drill bit and drill.

  1. Locate, mark and remove the factory rivets that attach the front wheelhouse assembly to the structure.

Note: The adhesive material will release from the structure by applying heat to approximately 400 degrees Fahrenheit (200 degrees Celsius). A noticeable popping sound can normally be heard when the adhesive releases.

  1. To complete the removal of the front wheelhouse panel, apply heat to the adhesive material to cause the adhesive to release and then remove the wheelhouse assembly from the vehicle.
(Photo courtesy of Ford media) – Sportscars like the venerable Ford Mustang often are on the extinction list of manufacturers eyeing other vehicle segments but still have legions of fans. That’s one more reason to keep your repair skills sharp.

Installation Procedure

Note: Note: Proper alignment of the wheelhouse assembly is important. The use of 3-dimensional measuring equipment is recommended when installing the part.

  1. Prior to applying adhesive, or welding, fit the wheelhouse assembly to the structure and check for proper alignment.
  2. With the part properly located and aligned, mark the locations for the rivets and welds recorded from the original part and drill the holes for the rivets.
  3. Remove the part from the vehicle to clean and prepare the surfaces for bonding and welding.

Note: Leave the Elpo-coating on the adhesive bonding surfaces of the service part to allow additional protection of the aluminum from galvanic corrosion.

  1. Scuff sand the bonding surfaces on the service part to remove the gloss from the Elpo-coating.
  2. Using a grinding disk or equivalent, prepare a bare steel surface on the bonding areas of the vehicle structure.
  3. Clean and prepare all welding surfaces.

Note: Refer to adhesive manufacturer’s recommendation for specific application and curing recommendations.

  1. Apply a bead of adhesive to all bonding surfaces on the vehicle structure and service part, per the adhesive manufacturer’s recommendations. Refer to GM’s Aluminum Panel Bonding instructions.

Note: Completely cover all bares surfaces with the adhesive.

  1. Using a small brush, spread a coat of the adhesive to cover the entire adhesive bonding surface to ensure proper corrosion protection.

Note: Do not allow the adhesive to cure off the vehicle prior to installing and aligning the part. Refer to adhesive manufacturer’s recommendations for specific cure times.

  1. Apply a bead of adhesive to the mating surface of the service part, per the adhesive manufacturer’s recommendations.

Note: Do not pull the panels apart after they’ve been joined together. Slide the panels against each other to realign the panels or proper joint strength may be affected.

Note: Proper alignment of the wheelhouse assembly is important. The use of 3-dimensional measuring equipment again is recommended when installing this part.

  1. Install the service part to the vehicle structure and check for proper alignment.
  2. Install the rivets along the bonding joint, at the original locations. Refer to the electronic parts catalog for the recommended rivets.
  3. Weld the service part at the original weld locations, as necessary.
  4. Install front tie bar attachment bracket, front outer upper rail and upper outer rail reinforcement bracket.
  5. Clean all welded surfaces.
  6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to GM’s Anti-Corrosion Treatment and Repair instructions.
  7. Paint the repaired area. Refer to GM’s Basecoat/Clearcoat Paint Systems instructions.
  8. Install all related panels and components.
  9. Enable the SIR system and then connect the negative battery cable. Refer to GM’s SIR Disabling and Enabling instructions.

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