Fiat barchetta Bodywork

Replacing body panels

Positioning the replacement part

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers and several spot welds as illustrat-
ed in the diagram.
3. Check that it is correctly positioned checking the alighment with the right and left front wings and
with the bonnet lid.

Welding the spare part

1. Weld the areas which are joined with the left and right wings using an oxyacetylene canister.
2. Spot weld, using a spot welder, along the contact area between the support underneath and the out-
er front cover

. . . . Spotwelding Brass welding

Copyright by Fiat Auto 65

~
Bodywork Fiat barchetta
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block,
2. Remove any weld slag using a disc grinder.

Protections

1. Apply the electro-phoretic protective treatment to the areas previously welded.

2. Seal the joins between the replacement part and the bodyshell using IVI 854210 transparent acrylic
sealant or an equivalent product.
3. Proceed with the painting and waxing stage.

66 Print no. 506.586

Fiat barchetta Bodywork
Replacing body panels

REPLACING OUTER COVER SUP-

PORT

The component for which the re-

placementprocedure is described is
,~~ Iii 1\\ /111\\ ,~_~~ highlighted
side.
in the diagram at the
'\\\RI I(~~ ~\\~\ f~~+ ~~>\ ~~W~7MO1.

Preliminary procedures
Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitable methods (jigs, templates or gauges).
Carry out any straightening operations required to the bodyshell before cutting the component.

After this operation check that the components not being replacedare in tact.
Preliminary dismantling
Remove the moveable parts of the bodywork and the electrical and mechanical components which
could impede the repair operations or be damaged during them. Also remove the outer front cover as de-
scribed previously.
Removing
Cut the cover support using a power saw following the dotted lines shown in the diagram below.

t:
=
jr-r;y--'OI.=--Lj~~~ I I IDIITII~~~ ILLL II ~
~ j uI
!
P3W067MO2
Whencarrying out the operationsdescribed,adherestrictly to the safetyprocedures.Wear
protective shoes, ear-muffs and gloves during the cutting operations,masksfor welding
and gloves during the welding operations,and a protective mask and gloves during the
painting operations.

Copyright by Fiat Auto 67

 Bodywork Fiat barchetta
Replacing body panels

Removing off cuts and preparing edges of bodyshell

1. Remove the weld points along the perimeter of the reinforcement brackets and along the inner sur-
face of the bonnet lid lock support using a special cutter.
2. Remove the metal off cuts using pliers.
3. Straighten the edges with a hammer and dolly block.
4. Remove the spot weld residues using a disc grinder.
5. Apply the electro-galvanizing paint or an equivalent product to the areas previously ground.

P3WO68MO1 ~
Preparing the spare part

1. Remove the anti-corrosion treatment from the entire perimeter of the inside and the outside of the re-
placement part using a disc grinder.
2. Apply the electro-galvanizing paint to the edges in contact with the bodyshell.

~
"-.,

--
(1/ ~ ~ j~~
~:;.-;:::-

P3WO68MO4

68 Print no. 506.586

~
 Fiat barchetta Bodywork
Replacing body panels

Positioning the replacement part

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers.
3. Check that the support is correctly positioned on the bodyshell.

Welding the spare part

1 Carry out the spot welding using a spot welder along the contact areabetween the front cover sup-
port, the two side reinforcement brackets and the bonnet lid lock housing support.

Spot welding

Copyright by Fiat Auto 69

~
 Bodywork Fiat barchetta
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block.
2. Remove any weld slag using a disc grinder.

Protections

1. Apply the electro-phoretic protective treatment to the areas previously welded.

2. Seal the joins between the replacement part and the bodyshell using IVI 854210 transparent acrylic
sealant or an equivalent product.
3. Proceed with the painting and waxing stage.

~
-=s~ 1/
;;~~?.:_r.=
~ @
~ i'(g\c I1E5f\
- - ~ .1, 8 I,

.mC~ - 0 IWl
[]j
--:-~

f
70 Print no. 506.586

~
 Fiat barchetta Bodywork
Replacing body panels

REPLACING FRONT WING

The component for which the re-

placement procedure is described is
highlighted in the diagram at the
side.

Preliminary procedures
Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitable methods (jigs, templates or gauges).

Carry out any straightening operations required to the bodyshell before cutting the component.

After this operation check that the components not being replacedare in tact.
Preliminary dismantling
Remove the moveable parts of the bodywork and the electical components which could impede the re-
pair operations or be damaged during them.
Removing
Cut the front wing using a power saw following the dotted lines shown in the diagrams below.

- -:-- ---
~~

--
~,~~
~ ~-==:
\~
0

/V\"-'\~ i
0 - ~' --:::~~
~-\ Id
<i!

When carrying out the operationsdescribed,adherestrictly to the safetyprocedures.Wear

protective shoes, ear-muffs and gloves during the cutting operations,masksfor welding
and gloves during the welding operations,and a protective mask and gloves during the
painting operations.

Copyright by Fiat Auto 71

~
Bodywork Fiat barchetta
Replacing body panels

Removing off cuts and preparing edges of bodyshell

1. Remove the weld points in the areas illustrated in the diagram, using a special cutter.
2. Removethe sealanton the edgesof the underdoorside memberand along the internal reinforcement.
3. Remove the metal off cuts using pliers.
4. Straighten the edges with a hammer and dolly block.
5. Remove the spot weld residues using a disc grinder.
6. Apply the electro-galvanizing paint or an equivalent product to the areas previously ground.

Preparing the spare part

1. Renew the sealant (1) on the replacement part in the areas illustrated.
2. Remove the anti-corrosion treatment from the entire perimeter of the inside and the outside of the re-
placement part using a disc grinder.
3. Apply the electro-galvanizing paint to the edges in contact with the bodyshell.

72 Print no. 506.586

Fiat barchetta Bodywork
Replacing body panels

Positioning the replacement part

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers and several spot welds as illustrat-
ed in the diagram.
3. Check that it is correctly positioned checking the alignment and the uniformity of the opening with
the door, the bonnet lid, the air intake cover and the external front cover.
4. After having carried out the appropriate checks, tack the replacement part with several spot welds
along the areas in contact with the front cover.

Welding the spare part

1. Carry out brass welding using an oxy-acetyelen canister in the areas in contact with the external front
cover.
2. Carry out spot welding using a spot welder along the area where the front suspension turret and
mounting bracket are in contact.
3. Carry out MIG welding for filling along the area in contact with the side panel.
4. Carry out continuous MIG welding at the edges where the wing is in contact with the underdoor side
member.
7
I
I '\
I
'"

~
dZ:
)~;

P3WO73MO2 P3WO73MO3

Spot welding MIGweldingforfilling Brass welding

Copyright by Fiat Auto 73

Bodywork Fiat barchetta
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block.
2. Remove any weld slag using a disc grinder.

P3WO71MO1

Protections

1. Apply the electro-phoretic protective treatment to the areas previously welded.

2. Seal the joins between the replacement part and the bodyshell using IVI 854210 transparent acrylic
sealant or an equivalent product.
3. Proceed with the painting and waxing stage.

"

,~
...?o~

ei!j-

:/
~ ~-

74 Print no. 506.586

Fiat barchetta Bodywork
Replacing body panels

REPLACING COMPLETE WIND-

SCREEN SEAL

The component for which the re-

placement procedure is described is
highlighted in the diagram at the
side.
P3WO75MO1

Preliminary procedures
Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitable methods (jigs, templates or gauges).

Carry out any straightening operations required to the bodyshell before cutting the component.

After this operation check that the components not being replaced are in tact.

Preliminary dismantling
Remove the moveable parts of the bodywork and the interior fittings which could impede the repair op-
erations or be damaged during them.

Removing
Cut the windscreen seal cover using a power saw along the dotted lines (1) and using a hammer and
chisel along the dotted lines (2), shown in the diagrams below.

/'
/
/
,/
/
'/
4",ri
5==~~V
~//

~ 0
I' P3WO75MO2 P3WO75MO3

Whencarrying out the operationsdescribed,adherestrictly to the safetyprocedures.Wear

protective shoes, ear-muffs and gloves during the cutting operations,masksfor welding
and gloves during the welding operations,and a protective mask and gloves during the
painting operations.

Copyright by Fiat Auto 75

Bodywork Fiat barchetta
Replacing body panels

Removing off cuts and preparing edges of bodyshell

1. Remove the weld points in the areas illustrated in the diagram using a special cutter.
2. Remove the metal off cuts using pliers.
3. Straighten the edges with a hammer and dolly block.
4. Remove the spot weld residues using a disc grinder.
5. Apply the electro-galvanizing paint or an equivalent product to the areas previously ground,

P3WO76MO2

Preparing the replacement internal reinforcement and the outer cover for the windscreen seal

1. Remove the anti-corrosion treatment from the entire perimeter of the inside and the outside of the re-
placement par't using a disc grinder.
2. Apply the electro-galvanizing paint to the edges in contact with the bodyshell.

P3WO76MO3 P3WO76MO4

76 Print no. 506.586

 Fiat barchetta Bodywork
Replacing body panels

Positioning the replacement internal reinforcement

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers
3. Check that it is correctly positioned checking the alignment figures for the reinforcement.

Welding the spare part

1. Carry out continuous MIG welding along the windscreen pillar reinforcement.
2. Carry out MIG welding for filling along the contact area between the reinforcement and the pillar
cover.

MIG welding for filling

Copyright by Fiat Auto 77

~
 Positioning the replacement windscreen seal cover

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers
3. Check that it is correctly positioned checking the alignment with the lowering window glass and
with the windscreen.

~~~~~~ ~~~~~~~~@~ '"

c=::

~
==~

::;;~~~~~~=s;;;;;~;:~.~

Welding the spare part

1. Carry out spot welding using a spot welder along the outer edges of the replacement part..
2. Carry out brass welding using an oxy-acetylene canister in the area in contact with the front pillar
cover.
-.

Spot welding Brass welding

78 Print no. 506.586

~
Fiat barchetta Bodywork
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block.
2. Remove any weld slag using a disc grinder.

Protections

1. Apply the electro-phoretic protective treatment to the reas previously welded.

2. Seal the joins between the two parts and with the bodyshell using IVI 854210 transparent acrylic
sealant or an equivalent product.
3. Proceed with the painting and waxing stage.

l_t~ l

Copyright by Fiat Auto 79

Bodywork Fiat barchetta
Replacing body panels

REPLACING FRONT CROSS

MEMBER

The component for which the re-

placement procedure is described is
highlighted in the diagram at the
side.

Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitab1e methods (jigs, templates or gauges).
Carry out any straightening operations required to the bodyshell before cutting the component.

After this operation check that the components not being replaced are in tact.

Preliminary dismantling
Remove the moveable parts of the bodywork and the electrical and mechanical components which
could impede the repair operations or be damaged during them. Also remove the external front cover
complete with support, as illustrated previously in this manual.
Removing
Cut the front cross member using a power saw along the side reinforcementbracketsand the edges of
the actual cross member.

P3WO80MO2
Whencarrying out the operationsdescribed,adherestrictly to the safetyprocedures.Wear
protective shoes, ear-muffs and gloves during the cutting operations,masks for welding
and gloves during the welding operations,and a protective mask and gloves during the
painting operations.

80 Print no. 506.586

Fiat barchetta Bodywork
Replacing body

Removing off cuts and preparing edges of bodyshell

1. Remove the weld points in the areas illustrated in the diagram using a special cutter.
2. Remove the metal off cuts using pliers.
3. Straighten the edges with a hammer and dolly block.
4. Remove the spot weld residues using a disc grinder.
5. Apply the electro-galvanizing paint or an equivalent product, to the areas previously ground.

P3WO81 MO1 P3W081 MOl

Preparing the replacement parts

1. A- Front cross member; B- Reinforcement brackets; C- Bonnet lid lock support.

1. Remove the anti-corrosion treatment from the entire perimeter of the inside and the outside of the re-
placement part using a disc grinder.
2. Apply the electro-galvanizing paint to the edges in contact with the bodyshell.

Copyright by Fiat Auto 81

 Bodywork Fiat barchetta
Replacing body panels

Positioning replacement reinforcement brackets

1. Position the front cross member and the two reinforcement brackets.
2. Fix the replacement parts to the bodyshell using self-locking pliers and with several spot welds fix the
brackets to the side panel.
3. Check that the brackets are correctly positioned in relation to the cross member, then remove the
front cross member.

Welding the spare part

1 Spot weld the reinforcementbracketsto the side panels using a spot welder.

I~
(

Lv I
\~rn I
J..~:::::~i1'
~~/ P3WO82MO3

Spot welding

82 Print no. 506.586

~
Fiat barchetta Bodywork
Replacing body panels

Positioning the replacement cross member

1. Placethe replacementcross member in position.

2. Fix the replacement part to the bodyshell and to the reinforcement brackets using self-locking pliers
and with several spot welds fix the front cross member to the side panels.
3. Check that the cross member is correctly positioned using the appropriate templates.

Welding the spare part

P3WO83MO2

. . .. Spotwelding MIG welding for filling

Copyright by Fiat Auto 83

 Bodywork Fiat barchetta
Replacing body panels

Positioning the replacement bonnet lid lock support

1. Place the bonnet lid lock support in position.

2. Fix the replacementpart to the crossmemberusing self-locking pliersand fix it temporarilywith sev-
eral spot welds.
3. Checkthat the replacementpart is correctly positioned on the cross member.

P3WO84MO1

Welding the spare part

1. Carry out MIG welding for filling in the inner contact area between the support and the cross mem-
2. Sfj"Qt weld the lock support in the side areas in contact with the cross member.

P3WO84MO2

Spot welding MIG welding for filling

84 Print no. 506.586

~
 Fiat barchetta Bodywork
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block.
2. Remove any weld slag using a disc grinder.

P3WO80MO1

Protections

1. Apply the electro-phoretic protective treatment to the areas previously welded.

2. Seal the joins between the two parts and with the bodyshell using IVI 854210 transparent acrylic
sealant or an equivalent product.
3. Proceed with the painting and waxing stage.
A

Copyright by Fiat Auto 85

 Bodywork Fiat barchetta
Replacing body panels

REPLACING OUTER REAR COV-

ER

The component for which the re-

placement procedure is described is
highlighted in the diagram at the
side.

Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitable methods (jigs, templates or gauges).
Carry out any straightening operations required to the bodyshell before cutting the component.

After this operation check that the components not being replaced are in tact.

Preliminary dismantling
Remove the moveable parts of the bodywork and the electrical components which could impede the re-
pair operations or be damaged during them.
Removing
Cut the rear outer cover for the vehicle using a power saw following the dotted lines shown in the dia-
gram below.

86 Print no. 506.586

~
 Fiat barchetta Bodywork
Replacing body panels

Removing off cuts and preparing edges of bodyshell

1. Remove the weld points in the areas illustrated in the diagram using a special cutter.
2. Remove the metal off cuts using pliers.
3. Straighten the edges with a hammer and dolly block.
4. Remove the spot weld residues using a disc grinder.
5. Apply the electro-galvanizing paint or an equivalent product, to the areas previously ground

P3WO87MO1

Preparing the spare part

1. Remove the anti-corrosion treatment from the entire perimeter of the inside and the outside of the re-
" placement part using a disc grinder.
2. Apply the electro-galvanizing paint to the edges in contact with the bodyshell.

Copyright by Fiat Auto 87

 Bodywork Fiat barchetta
Replacing body panels

Positioning the replacement part

1. Carefully place the replacement part in position.

2. Fix the replacement part to the bodyshell using self-locking pliers and several spot welds as illustrat-
ed in the diagram.
3. Check that it is correctly positioned checking the alignment with the wings and also check the uni-
formity of the opening with the boot lid.

Welding the spare part

1. Spot weld using a spot welder along the areas in contact with the rear wings, then brass weld using
an oxy-acetylene canister by the previously welded areas.
2. Spot weld using a spot welder along the contact area between the outer cover and the support for the
actual cover and in the contact areawith the rearcross member.

Spot welding Brass welding

88 Print no. 506.586

~
 Bodywork
Replacing body panels

Finishing operations

1. Correct any distortions to the panel using a hammer and dolly block.
2. Remove any weld slag using a disc grinder.

P3WO86MO1

Protections

1. Apply the electro-phoretic protective treatment to the areas previously welded.

2. Seal the joins between the replacement part and the bodyshell using IVI 854210 transparent acrylic
sealant oran equivalent product.
~ 3. Proceed with the painting and waxing stage.

P3WO89MO1

Copyright by Fiat Auto

 Bodywork Fiat barchetta
Replacing body panels

REPLACING FRONT PANEL

The component for which the re-

placement procedure is described is
highlighted in the diagram at the
side.

Preliminary procedures
Establish the extent of the damage, check if there are distortions to the connected components by
checking the bodyshell alignment figures, using suitable methods (jigs, templates or gauges).

Carry out any straightening operations required to the bodyshell before cutting the component,

After this operation check that the components not being replacedare in tact.
Preliminary dismantling
Remove the moveable parts of the bodywork and the mechanical and electrical components which
could impede the repair operations or be damaged during them. Also remove the front wing and the
front cover complete with support as described previously.
Removing
Cut the front panel of the vehicle using a power saw following the dotted lines illustrated in the diagram
below.

-~
F'"

pT
-:::::::::-

~- [

'" -..::=--
/
~

-
P3WO90MO2
Whencarrying out the operationsdescribed,adherestrictly to the safetyprocedures.Wear
protective shoes, ear-muffs and gloves during the cutting operations,masksfor welding
and gloves during the welding operations,and a protective mask and gloves during the
painting operations.

90 Print no. 506.586