Cutting out side roof paneling - AR65.10-P-1020-01PC

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)

Fig 2: Identifying Cutting Templates (203 589 06 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner

Scribe cutting points at A, B and C pillars.
Scribe cutting point at A-pillar to suit new part. Use cutting template at B and C pillars.
Cut at cutting point using body saw (areas A, B and C).

Fig 3: Identifying Cutting Points - Areas A-C

Fig 4: Identifying Spot Welds - Areas D-H
Uncover spot welds and mill off using spot weld miller (areas D and E).
Uncover spot welds and drill using 6 mm bit (areas F and G).
Uncover spot welds and mill off using ball-type miller cutter (area H).
Heat side roof paneling in checked area using hot air gun.
Checked areas are foam-protected.
Remove side roof paneling.
Take care not to damage internal foam parts.
Grind side paneling connection surfaces to bare metal (checked areas). Grind spot weld flanges to bare metal on both sides.
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot welding flanges with zinc dust paint.

Fig 5: Identifying Side Paneling Connection Surfaces