Cut Off A-Pillar - Ar63.20-P-1100-01LWR

Model 205.4 

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1. Expose spot welds on roof frame (8) and cut out (areas A).
2. Expose MIG solder seams on roof frame (8) and cut (areas B).
3. Remove roof frame (8).

   The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

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4. Expose spot welds on A-pillar paneling (5) and cut out (areas E).

   Cut out joint spot welds on A-pillar paneling (5) and A-pillar reinforcement through two sheet metal thicknesses.

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5. Heat A-pillar paneling (5) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

6. Remove A-pillar paneling (5).

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7. Mark separating point on mounting rail (10) and cut (area C).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions:

   c = approx. 140 mm

8. Expose spot welds on mounting rail (10) and cut out (areas D).
9. Remove mounting rail (10)

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10. Mark separating point on A-pillar reinforcement (6) and cut (area F).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions:

    f = approx. 65 mm (measured from Y-marking)

11. Expose MIG solder seams on A-pillar reinforcement (6) and cut out (areas H).
12. Expose spot welds on A-pillar reinforcement (6) and cut out (areas I).

    Joint spot welds on A-pillar reinforcement (6) and A-pillar inner panel must be cut out through two panel thicknesses.

13. Expose spot welds on A-pillar reinforcement (6) and cut out (areas J).

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14. Heat crosshatched areas on A-pillar reinforcement (6).

    Cross-hatched areas are bonded with adhesive.

    Heat crosshatched areas from inside (areas K).

15. Remove A-pillar reinforcement (6).

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16. Mark separating points on A-pillar inner panel (7) and cut (area M).

    Do not make the cuts too deep.

    Otherwise the components below can be damaged and weakened.

    Dimensions:

    m = approx.60 mm

17. Expose MIG solder seams on A-pillar inner panel (7) and cut out (areas N).
18. Expose spot welds on A-pillar inner panel (7) and cut out (areas O₁ and O₂ ).

    Cut out spot welds from inside (area C2).

19. Expose spot welds on A-pillar inner panel (7) and drill with Ø 6.5 mm bit (areas P).
20. Expose laser seam on A-pillar inner panel (7) and cut out (area L).
21. Heat A-pillar inner panel (7) in cross-hatched area.

    Cross-hatched area is bonded.

22. Remove A-pillar inner panel (7).

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23. Sand down mating surfaces to bare metal in cross-hatched areas.

    Sand down spot weld flanges to bare metal on both sides.

24. Remove grinding dust and drill chips.
25. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas Q).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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