Gm Global Technolgoy Operations, Inc.

James G Bouck

Wieslaw S Zaydel

Hulki Aldikacti

Method and apparatus for attachment of a plastic body outer panel on a dimensionally variable underlying body structure includes a plurality of plastic filled attachment blocks welded at selected points on the body structure to approximately align with apertured mounting faces previously provided on the plastic panels. The body structure is mounted within a locating and machining fixture and each of the plurality of attachment blocks are milled to provide panel support face on each attachment block precisely dimensioned relative panel support faces on each other attachment block. A fastener hole is drilled in the panel support face of each attachment block at a precise location relative the fastener hole drilled in each of the other panel support faces. The body structure is removed from the fixture and the plastic panels are attached thereto by installing fasteners through apertured mounting faces of each panel and through the fastener holes. The precise drilled location of the fastener holes cause each of the plastic panels to be precisely located and spaced relative the adjacent plastic panels. The fasteners hold the mounting faces of the plastic panels in contact with the precisely machined panel support faces of the attachment blocks so that each body outer panel is mounted without distortion of its visible outer surface and the surface of each of the plastic panels is mounted in precise surface alignment with each adjacent plastic panel.

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Clarkston, MI, United States of America

James G Bouck