Riveted and bonded aluminum, not welded steel
On an aluminum-intensive Land Rover structure, self-piercing rivets hold the panels in position and structural adhesive carries load across the joint. Both are specified precisely: rivet type and length by location, adhesive product, surface preparation, open time, and cure. Rivets are single-use and are drilled out and replaced rather than reused, and the procedure names which bonded joints may be separated at all.
All of that happens in a separated aluminum area with dedicated tooling and consumables. Steel particles that settle onto aluminum embed in the softer metal and start galvanic corrosion, which surfaces as blistering under the paint a year or two after the repair — long enough that nobody connects the two.
Structural work is measured in three dimensions against the factory specification before anything is pulled and re-measured until it reads within tolerance. Straightening heat is measured rather than judged, because aluminum permanently anneals above its specified range while giving no visual indication that it has.
- —Self-piercing rivets replaced to specification, never reused
- —Structural adhesive applied per procedure, with full cure observed
- —Separated aluminum area with dedicated tooling
- —Three-dimensional structural measuring, before and after
- —Air suspension ride height set before ADAS calibration
- —Corrosion protection and cavity treatment restored
