41 00... Sectional Repair Of Extruded Aluminum Sections With Repair Elements

In the case of a partial replacement piece, an aluminum extruded section is cut at a point described in the repair instructions.

The following illustrations serve as schematic representations.

Mark component in accordance with distance A and cut.

Fig 1: Aluminum Section Dimension

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Adjust new part to fit with straightening attachment or universal mount.

Drill holes in center of upper (1) and lower (2) cutting edges.

Hole diameter 10 mm.

Remove paint in upper and lower profile chambers on body and new part. Measured from cutting edge, min. 50 mm deep into each profile chamber.

The inside surfaces of the profile chambers must be smooth. They must not feature any raised areas. If necessary, surface-grind rest of rivet joints in chambers.

Fig 2: Holes Of Upper And Lower Centre Cutting Edges Dimension

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Grind outside of repair elements until bare.

NOTE: The ribs on the repair elements must not be ground off.

Insert screws (2) into repair elements (1).

Coat repair elements (1) with, see ADHESIVE .

Fig 3: Repair Elements Of Adhesive With Screw

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Push repair elements (1) into upper and lower profile chambers on body.

Fig 4: Repair Element Of Profile Chamber

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Push new part over repair elements and adjust to fit with straightening attachment or universal mount.

Expand repair elements with screws (1) and (2) until a slight curved surface can be discerned at screws (1) and (2).

After curing, remove screws (1) and (2).

Seal cutting lines and bores with PVC sealing compound (refer to BMW Parts Service).

Fig 5: Profile Chamber Screws

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