Assembly Plan

Lithium EV Battery – 70 mph

GENERAL DESCRIPTION

  • Range: 70, 140, 210 miles

  • Nominal Voltage: 400 V

  • Nominal Capacity: 50 Ah, 100 Ah, 137.5 Ah

  • Estimated Energy: ~20 kWh, ~40 kWh, ~55 kWh

  • AC Charger: 6.6 kW (220 V) / 11 kW (3-phase)

  • DC Option: 30, 40 kW (40–60 min)

  • Connector: CCS2

Components

Tools

#

BTPK-001

Part

Lithium Cells

Name

21700 or Automotive Prismatic LFP (Superior Safety and Cycle Life)

#

HRBT-001

Part

Mechanical

Name

Torque Wrench 20–200 Nm and 200–600 Nm

#

BTPK-002

Part

BMS

Name

Automotive BMS With CAN Bus + Contactor Control

#

HRBT-002

Part

Mechanical

Name

Lifting Equipment Hydraulic Jack + Jack Stands

#

BTPK-003

Part

Thermal System Type (Cooling)

Name

Liquid Cooling

#

HRBT-003

Part

Mechanical

Name

HRBT-003

#

BTPK-004

Part

Contactor type

Name

(+ / – +) Pre-charge (Sealed Automotive)

#

HRBT-004

Part

Mechanical

Name

Ball joint separator (if applicable)

#

BTPK-005

Part

HV Connectors

Name

Orange Automotive + HVIL

#

HRBT-005

Part

Mechanical

Name

Caliper / Vernier Caliper

#

BTPK-006

Part

Fuse Type (Protection)

Name

Main HV + internal fuses (optional but recommended)

#

HRBT-006

Part

Mechanical

Name

Laser level or alignment tape

#

BTPK-007

Part

Busbar Type / Connections

Name

Nickel-Copper (Ni-Cu) or high-grade thick nickel

#

HRBT-007

Part

HV/LV Electrical

Name

CAT III 1000V Multimeter

#

BTPK-008

Part

Cooling

Name

Liquid cooling

#

HRBT-008

Part

HV/LV Electrical

Name

500V / 1000V Megger (Insulation Tester)

#

BTPK-009

Part

Sealed box

Name

Reinforced aluminum, IP67 sealed

#

HRBT-009

Part

HV/LV Electrical

Name

Laptop with inverter/VCU software

#

BTPK-010

Part

Sensor Type

Name

Recommended Insulation Monitoring Device (IMD)

#

HRBT-010

Part

HV/LV Electrical

Name

Clamp meter (o Current clamp)

#

BTPK-011

Part

Charger

Name

6.6 kW AC Home Charger (On-Board Charger) Type 1 / Type 2 Support

#

HRBT-011

Part

HV/LV Electrical

Name

Insulated tool kit

#

BTPK-012

Part

DC Fast Charger (o DCFC)

Name

CCS / GB/T / CHAdeMO support depending on region 60–80 kW actual DC CAN/PLC communication with BMS

#

HRBT-012

Part

Consumables

Name

Loctite (Blue)

#

BTPK-013

Part

Pack labels

Name

Nominal voltage, kWh, serial, BMS

#

HRBT-013

Part

Consumables

Name

Automotive cable ties

#

BTPK-014

Part

Installation manual

Name

Installation manual

#

HRBT-014

Part

Consumables

Name

Corrugated loom

#

BTPK-015

Part

Torque specs

Name

Manufacturer's recommended values for a part, machinery, or vehicle regarding the exact torque to be applied to a bolt, nut, or fastener during installation.

#


HRBT-015
HRBT-016
HRBT-017

Part


Consumables
Consumables
Consumables

Name


Torque marker
Thermal paste
QC Labels

Assembly Plan

(Applies to 70-mile, 140-mile, and 210-mile ranges)

Integration of 3 Battery Packs

Steps

Name

Base Specifications

Description

Installing a finished battery (e.g., 400V 20kWh / 40kWh / 55kWh) into the vehicle, including:

  • Mechanical Mounting
  • HV Connections (High Voltage)
  • LV Connections (CAN / Signals)
  • HV Safety
  • Functional Testing
  • Final Checklist

    • Duration

    Parts needed

    Skills

    QC Inspector tecnico HV

    Steps

    Step 1

    Name

    Receiving + Inspection

    Description

    Documentation Verification
     1. Check pack label: Nominal voltage, kWh, serial, BMS.
    2. Confirm installation manual.
    3. Confirm supplier torque specs.

    Incoming Visual Inspection
    1. Check for impacts, dents, or loose connectors.
    2. Verify inclusion of:
    3. HV Fuse
    4. Main Contactor
    5. Service Disconnect (o MSD - Manual Service Disconnect)
    6. HV+ Connector
    7. HV- Connector
    8. LV Connector (BMS/CAN)
    9. Vent line (if applicable)

    Duration

    0.3

    Parts needed

    BTPK-005 BTPK-006 BTPK-007 BTPK-008 BTPK-009 BTPK-010 BTPK-013 BTPK-014 BTPK-015

    Skills

    QC Inspector

    Steps

    Step 2

    Name

    Vehicle Preparation (Battery Area)

    Description

    Support Cleaning and Review
     1. Check pack base
    2. Check mounting points
    3. Check vibration isolation

    Bolting and Final Torque
    1. Anti-vibration pads (EPDM or Neoprene)
    2.Thermal insulator (if applicable)

    Duration

    0.4

    Parts needed

    BTPK-006 BTPK-007 BTPK-008 BTPK-009 BTPK-010

    Skills

    QC Inspector HV Technician

    Steps

    Step 3

    Name

    Mechanical Battery Mounting

    Description

    Pack Positioning with Crane or Lift Table
     1. Use lift table or mini crane
    2. Align with mounting points

    Bolting and Final Torque
    1. Install M10 or M12 bolts
    2.Apply controlled torque
    3. Apply torque marker (paint mark)

    Underbody Protection Installation (Skid Plate)
    1. Metal or composite bottom plate
    2. Bolts + lock washers (Grower)

    Duration

    1

    Parts needed

    BTPK-001 BTPK-002 BTPK-003 BTPK-004 BTPK-005 BTPK-006 BTPK-007 BTPK-008 BTPK-009 BTPK-010

    Skills

    QC Inspector HV Technician

    Steps

    Step 4

    Name

    HV Connection (High Voltage)

    Description

    Pack Positioning with Crane or Lift Table
     1. Use lift table or mini crane
    2. Align with mounting points

    Bolting and Final Torque
    1. Install M10 or M12 bolts
    2.Apply controlled torque
    3. Apply torque marker (paint mark) Underbody Protection Installation (Skid Plate)
    1. Metal or composite bottom plate
    2. Bolts + lock washers (Grower)

    Duration

    1

    Parts needed

    BTPK-004 BTPK-005 BTPK-006 BTPK-007

    Skills

    The technician must be familiar with Voltage.

    This phase must be performed with the Service Disconnect removed. HV Technician

    Steps

    Step 5

    Name

    LV Connection (Signals / Communication)

    Description

    CAN Connection (BMS → VCU)
     1. CAN High / CAN Low
    2. Confirm termination resistance (120Ω)

    Auxiliary signals connection
    1. Wake-up
    2.Enable
    3.Interlock (HVIL)
    4. Ignition signal

    Duration

    0.40

    Parts needed

    BTPK-005 BTPK-006 BTPK-007

    Skills

    HV Technician

    Steps

    Step 6

    Name

    Thermal system (if applicable)

    Description

    Connect coolant hoses
    1. Inlet / Outlet
    2. Clamps
    3. Check for leaks

    System bleeding
    1.Air bleeding (o Air purging)
    2.Confirm flow

    Duration

    1

    Parts needed

    BTPK-002

    Skills

    HV Technician

    Steps

    Step 7

    Name

    HV Safety + Checklist

    Description

    Insulation test (Megger test)
    1. HV to chassis
    2. HV to ground
    3. Typical objective: > 1MΩ (standard dependent)

    HVIL Verification
    1.HVIL Verification


    Service Disconnect Installation
     1. Insert and secure
    2. Confirm it is locked

    Duration

    0.40

    Parts needed

    BTPK-001 BTPK-002 BTPK-003 BTPK-004 BTPK-005 BTPK-006 BTPK-007 BTPK-008 BTPK-009 BTPK-010

    Skills

    HV Technician

    Steps

    Step 8

    Name

    Power-on and functional testing

    Description

    System Energization (Pre-charge)

    • Confirm correct pre-charge
    • Confirm main contactor
    BMS Diagnostics Read:
    • Total voltage
    • SOC
    • Temperatures
    • Balancing
    • Alarms
    AC Charging Test
    • Connect AC charger
    • Confirm stable current
    • Confirm no errors
    DC Charging Test
    • Confirm handshake
    • Confirm voltage and current
    Movement Test (Low Speed)
    • 5–10 meter test
    • Confirm no faults

    Duration

    1.20

    Parts needed

    BTPK-011 BTPK-012

    Skills

    QC Inspector

    Steps

    Step 9

    Name

    Final Closure and Release

    Description

    Secure harness and routing

    • Zip ties / Cable ties
    • Anti-friction protection
    • Covers
    Labeling and quality control
    • Serial number label
    • Traceability log registration

    Duration

    0.30

    Parts needed

    BTPK-001 BTPK-002 BTPK-003 BTPK-004 BTPK-005 BTPK-006 BTPK-007 BTPK-008 BTPK-009 BTPK-010 BTPK-011 BTPK-012

    Skills

    QC Inspector

    Steps

    Name

    Final Checklist

    Description

    • Torque marked on main bolts
    • HV cables without friction and with protection
    • HVIL functioning
    • Megger test OK
    • CAN communication OK
    • AC charging OK
    • Pre-charge OK
    • No alarms in BMS

    Duration

    6

    Parts needed

    Skills

    QC Inspector

    Assembly Plan

    Electric Motor—Spec Sheet (80 kW 400 V)

    GENERAL DESCRIPTION

    • Nominal System Voltage: 400 VDC

    • Operating Voltage Range: 300–450 VDC

    • Motor Type: PMSM / IPMSM (Permanent Magnet)

    • Continuous Power: 80–90 kW

    • Maximum Power (Peak): 140 kW (10–60 s peak)

    Parts

    Tools

    #

    MTR-001

    Part

    Wheel hub

    Name

    Wheel hub pcd 4x100 + bolts

    #

    HMTR-001

    Part

    Mechanics

    Name

    Torque wrenches: 20–200 nm and 200–600 nm

    #

    MTR-002

    Part

    Shock absorbers

    Name

    2 shock absorbers + hardware

    #

    HMTR-002

    Part

    Mechanics

    Name

    Hydraulic jack + jack stands

    #

    MTR-003

    Part

    Swinging arm (swingarm)

    Name

    2 swinging arms (swingarms)

    #

    HMTR-003

    Part

    Mechanics

    Name

    Hoist / scissor lift table

    #

    MTR-004

    Part

    Disc brake axle with rear motor

    Name

  • disc brake axle with rear motor

  • (a) custom width 1800 mm

  • (b) 400 v 80 kw dc motor

  • (c) disc brakes

  • (d) 4x100 wheel bolt pattern

  • mounting hardware

    • #

    HMTR-004

    Part

    Mechanics

    Name

    Ball joint separator (if applicable)

    #

    MTR-005

    Part

    Dc motor

    Name

    400 v 80 kw dc motor controller + hardware + bracket (if applicable)

    #

    HMTR-005

    Part

    Mechanics

    Name

    Manual press (if bushings require pressure)

    #

    MTR-006

    Part

    Upper and lower steering columns

    Name

    2 upper and lower steering columns

    #

    HMTR-006

    Part

    Brakes

    Name

    Brake bleed kit

    #

    MTR-007

    Part

    steering wheel

    Name

    1 steering wheel

    #

    HMTR-007

    Part

    Brakes

    Name

    DOT 4 brake fluid

    #

    MTR-008

    Part

    Brake system

    Name

  • brake system

  • (1) brake pedal

  • (2) brake hose

    • #

    HMTR-008

    Part

    Brakes

    Name

    Brake bleeder wrench

    #

    MTR-009

    Part

    Accelerator pedal

    Name

    1 accelerator pedal

    #

    HMTR-009

    Part

    Electrical

    Name

    CAT III 1000V multimeter

    #

    MTR-010

    Part

    gear shifter / gear lever

    Name

    Gear Shifter (Forward and Reverse)

    #

    HMTR-010

    Part

    Electrical

    Name

    Megger 500V / 1000V

    #

    MTR-011

    Part

    Wiring

    Name

    High-Quality Wiring System

    #

    HMTR-011

    Part

    Electrical

    Name

    Isolated HV Tools (Insulated HV Tools)

    #

    MTR-012

    Part

    Wheels

    Name

    #

    HMTR-012

    Part

    Electrical

    Name

    Cable Ties + Corrugated Sleeve

    #

    MTR-013

    Part

    Support

    Name

    2 Supports

    #

    Part

    Name

    #

    MTR-014

    Part

    Suspensions

    Name

    2 Suspensions + Hardware (Bolts and Nuts)

    #

    Part

    Name

    Assembly Plan

    (Motor Kit + Axle + Steering + Brakes)

    Steps

    Name

    Base Specifications

    Description

    Application: Full Van EV Chassis

    • Rear Axle: 1800 mm custom
    • Motor: 400V 80kW DC
    • Wheel PCD: 4x100
    • Brakes: Disc (x4)

    Duration

    Parts needed

    Skills

    EV Mechanical Technician HV Electrical Technician LV Electrical Technician QC Inspector

    Steps

    Step 1

    Name

    Chassis Preparation

    Description

    Objective: Prepare the chassis for suspension + rear axle mounting.

    1. Clean rear and front mounting areas
    2. Inspect anchor points
    3. Check threads, drillings, and alignment
    4. Prepare hardware (bolts/nuts) and tools

    Duration

    0.30

    Parts needed

    Skills

    EV Mechanical Technician

    Steps

    Step 2

    Name

    Support Mounting (2 supports)

    Description

    Support Mounting (2 supports)

    1. Install 2 main system supports (brackets)
    2. Align with the chassis
    3. Bolt down
    4. Apply torque + torque marker

    Duration

    1

    Parts needed

    MTR-013

    Skills

    EV Mechanical Technician

    Steps

    Step 3

    Name

    Mounting of swingarms (2 pieces)

    Description

  • Position left swingarm
  • Position right swingarm
  • Install bolts + bushings
  • Verify free travel without friction
  • Final torque

    • Duration

    1

    Parts needed


    MTR-001
    MTR-003

    Skills

    EV Mechanical Technician

    Steps

    Step 4

    Name

    Suspension Mounting (2 suspensions)

    Description

    We define 'suspensions' as the suspension assemblies or the control arms and mounts.

  • Install left-hand suspension assembly
  • Install right-hand suspension assembly
  • Align with control arms
  • Adjustment and torque

    • Duration

    0.45

    Parts needed

    MTR-014

    Skills

    EV Mechanical Technician

    Steps

    Step 5

    Name

    Shock absorber installation

    Description

  • Install left-hand shock absorber
  • Install right-hand shock absorber
  • Secure caps and bolts
  • Verify travel without bottoming out

    • Duration

    1.00

    Parts needed

    MTR-002

    Skills

    EV Mechanical Technician

    Steps

    Step 6

    Name

    Rear axle mounting with motor and brakes

    Description

    Critical part of the kit Rear motor disc brake axle (a) 1800 mm width (b) 400V 80kW DC (c) Disc brakes (d) PCD 4x100

    1. Lift the axle using a jack/hoist
    2. Align the axle with the swingarms
    3. Insert main bolts
    4. Adjust and center
    5. Final torque
    6. Confirm the axle rotates freely (no brake drag)

    Duration

    2.3

    Parts needed

    MTR-004

    Skills

    EV Mechanical Technician

    Steps

    Step 7

    Name

    Montaje de cubos/bujes de rueda (PCD 4x100)

    Description

    1-Install left-hand hub 2-Install right-hand hub 3-Confirm PCD 4x100 4-Apply torque 5-Check play (no slack)

    Duration

    1

    Parts needed

    MTR-001

    Skills

    EV Mechanical Technician

    Steps

    Step 8

    Name

    Wheel Mounting

    Description

  • 1 . Mount wheels
  • 2. Cross-tighten
  • 3. Final torque
  • 4. Verify no interference with brakes

    • Duration

    0.30

    Parts needed

    MTR-012

    Skills

    EV Mechanical Technician

    BRAKE SYSTEM (Mechanical + Hydraulic)

    Steps

    Step 9

    Name

    Brake Pedal Installation

    Description

  • Install brake pedal in cabin
  • Secure pivot and return spring
  • Adjust pedal height
  • Verify pedal travel

    • Duration

    0.30

    Parts needed

    MTR-008

    Skills

    EV Mechanical Technician

    Steps

    Step 10

    Name

    Brake Hose Installation

    Description

  • Install hoses to rear axle
  • Secure with clips
  • Connect to disc brakes
  • Check for kinks or rubbing

    • Duration

    0.45

    Parts needed

    MTR-008

    Skills

    EV Mechanical Technician

    Steps

    Step 11

    Name

    Brake System Bleeding and Testing

    Description

  • Fill with DOT4 fluid
  • Bleed left-hand line
  • Bleed right-hand line
  • Check for leaks
  • Firm pedal test

    • Duration

    0.45

    Parts needed

    HMTR-007

    Skills

    EV Mechanical Technician QC Inspector

    Steps

    Step 11

    Name

    Brake System Bleeding and Testing

    Description

  • Fill with DOT4 fluid
  • Bleed left-hand line
  • Bleed right-hand line
  • Check for leaks
  • Firm pedal test

    • Duration

    0.45

    Parts needed

    HMTR-007

    Skills

    EV Mechanical Technician QC Inspector

    Metalwork Assembly Plan - Wortix Full Van EV

    • Metal Chassis
    • Cabin Cage / Bodywork
    • Mounts and Assembly
    • Protection and Rigidity

    Metalwork Assembly Plan (Chassis + Cage + Brackets + Rigidity)

    Steps

    Name

    Base Specifications

    Description

    Application: Full Van EV / flatbed, cargo Objective: Manufacture and integrate the metal skeleton ready to receive:

    • suspension + drive axle
    • battery
    • cabin (interiors)
    • harnesses and systems

    Duration

    -

    Parts Needed

    -

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)
    • Painting / Protection Technician (Level B)

    Steps

    Step 1

    Name

    Steering Wheel Installation

    Description

    Objective: Avoid errors in parts, lengths, and positioning

    1. Identify all parts by code
    2. Review thicknesses and material (tube / sheet)
    3. Mark the center of the chassis (line 0)
    4. Prepare jig / template and reference points

    Duration

    1

    Parts needed

    MTL-001 MTL-002 MTL-003 MTL-004 MTL-005 MTL-006 MTL-007 MTL-008 MTL-009 MTL-010 MTL-011 MTL-012 MTL-013 MTL-014 MTL-015 MTL-016

    Skills

    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 2

    Name

    Chassis base assembly (stringers + crossmembers)

    Description

    1. Place 2 longitudinal stringers on jig
    2. Align and measure diagonals (X)
    3. Place front crossmembers
    4. Place central crossmembers
    5. Place rear crossmembers
    6. Tack weld all points
    7. Re-verify diagonals and squareness
    8. Final welding by sequence (anti-deformation)

    Duration

    6

    Parts needed

    MTL-001 MTL-002 MTL-014

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 3

    Name

    Front subframe installation

    Description

    Objective: Prepare the area where steering + front suspension will be mounted.

    1. Position front subframe on jig
    2. Align with the chassis center axis
    3. Tack weld
    4. Measure heights and level
    5. Final welding

    Duration

    4

    Parts needed

    MTL-003 MTL-014

    Skills

    Técnico Soldador Estructural Técnico Armador / Metalmecánico

    Steps

    Step 4

    Name

    Rear subframe installation

    Description

    Objective: Prepare the area where the drive axle will be mounted.

    1. Position rear subframe
    2. Verify distance between suspension points
    3. Tack weld
    4. Review diagonals
    5. Final welding

    Duration

    4

    Parts needed

    MTL-003 MTL-014

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 5

    Name

    Battery tray / pack support structure

    Description

    Objective: Structural assembly for the battery pack (critical zone).

    1. Place tray in position
    2. Verify:
      • ground clearance
      • fixing points
      • maintenance access
    3. Tack weld
    4. Weld by sequence
    5. Install local reinforcements

    Duration

    5

    Parts needed

    MTL-009

    Skills

    • Structural Welder Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 6

    Name

    Motor / powertrain mounts

    Description

    Objective: Prepare the points for mounting the motor/axle kit.

    1. Position motor mounts (according to the plan)
    2. Verify height and alignment
    3. Tack weld
    4. Final welding
    5. Check that it does not interfere with the battery tray

    Duration

    3

    Parts needed

    MTL-010 MTL-014

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician

    Steps

    Step 7

    Name

    Control arms / suspension links (points)

    Description

    ALERT: metal mounting points are manufactured/installed here.

    1. Position control arm brackets
    2. Verify left/right symmetry
    3. Tack weld
    4. Final welding
    5. Measure distance between points

    Duration

    4

    Parts needed

    MTL-012 MTL-014

    Skills

    • Structural Welder Technician
    • QC Metrology Inspector (Level B)

    CABIN CAGE / BODYWORK

    Steps

    Step 8

    Name

    Cabin floor (floor panel)

    Description

    Objective: Create the cabin base and cargo area.

    1. Present floor panel on chassis
    2. Align with center and reference points
    3. Tack weld on edges
    4. Weld bead by sections
    5. Seal joints (if applicable)

    Duration

    3

    Parts needed

    MTL-007 MTL-015

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician

    Steps

    Step 9

    Name

    Installation of pillars A / B / C

    Description

    Objective: Assemble the vertical cage.

    1. Mount left and right A-pillars
    2. Verify inclination and symmetry
    3. Mount B-pillar
    4. Mount C-pillar
    5. Complete tack welding
    6. Measure cabin diagonals
    7. Final welding

    Duration

    5

    Parts needed

    MTL-005 MTL-015

    Skills

    • Structural Welder Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 10

    Name

    Roof panel

    Description

    Objective: Close the upper structure and provide rigidity.

    1. Present roof panel
    2. Align with pillars
    3. Tack weld perimeter
    4. Weld by sequence (to prevent deformation)
    5. Check for waviness

    Duration

    3

    Parts needed

    MTL-004 MTL-015

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician

    Steps

    Step 11

    Name

    Side panels / body panels

    Description

    Objective: Close sides and provide shape.

    1. Present left side panel
    2. Present right side panel
    3. Align with pillars
    4. Tack weld
    5. Final welding (or rivet if design allows)
    6. Verify symmetry

    Duration

    6

    Parts needed

    MTL-008 MTL-015

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 12

    Name

    Door assembly (metal structure)

    Description

    Objective: Prepare doors for subsequent hardware installation.

    1. Assemble door interior structure
    2. Join exterior panel
    3. Verify:
      • alignment
      • perimeter gap
    4. Tack weld
    5. Final welding
    6. Check for warping

    Duration

    8

    Parts needed

    MTL-006 MTL-015

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician

    PROTECTION AND RIGIDITY

    Steps

    Step 13

    Name

    Reinforcement plates / lower panels

    Description

    Objective: Rigidity + impact and torsion protection.

    1. Install plates in:
      • sides
      • subframe joints
      • battery zone
    2. Tack weld
    3. Final welding
    4. Check that it does not interfere with harnesses

    Duration

    4

    Parts needed

    MTL-013

    Skills

    • Structural Welder Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 14

    Name

    Seat frames

    Description

    Objective: Secure structure for driver and passenger.

    1. Position frame
    2. Verify ergonomics (height and distance)
    3. Tack weld
    4. Final welding
    5. Verify level

    Duration

    2

    Parts needed

    MTL-011

    Skills

    • Structural Welder Technician
    • Assembly / Metalworking Technician

    Steps

    Step 15

    Name

    Weld finishing + surface preparation

    Description

    Objective: Prepare for anti-corrosive painting.

    1. Grinding of weld beads (where applicable)
    2. Removal of burrs
    3. Cleaning with degreaser
    4. Visual inspection of welds

    Duration

    4

    Parts needed

    Skills

    • Assembly / Metalworking Technician
    • QC Metrology Inspector (Level B)

    Steps

    Step 16

    Name

    Anti-corrosive protection + sealing

    Description

    Objective: Protect the chassis and bodywork against oxidation.

    1. Apply epoxy primer
    2. Apply seam sealer to joints
    3. Paint or coating
    4. Controlled drying

    Duration

    6

    Parts needed

    Painting consumables

    Skills

    • QC Metrology Inspector (Level B)
    • Painting / Protection Technician (Level B)

    Name

    Critical points (most frequent causes of rework)

    Description

    • Chassis diagonals out of tolerance
    • Misaligned A/B/C pillars (doors do not close)
    • Welding deformation on roof and side panels
    • Misplaced battery tray (pack does not fit)
    • Non-symmetrical suspension points
    • Lack of reinforcement in subframe joints

    Duration

    68