Welding in front inner side member

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Welding In Front Inner Side Member

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE:

When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

FRONT INNER SIDE MEMBER WELDING PROCEDURE

No.	Procedure	Instructions
1	Spot-welding inner side member/web plate	Spot-weld web plate to side member -B, C-A- . See Fig 1 .
2	Welding inner firewall/side member under shielding gas	Plug-weld the predrilled holes -D- . See Fig 1 .
3	Welding inner side member/ base side member under shielding gas.	Weld the inner side member/base side member with a full butt weld -F, E- . See Fig 1 .
4	Inner side member/firewall	Weld inner side member/firewall -G- . See Fig 1 .
	Replacing front wall	See REPLACING FRONT WALL
	Replacing wheel housing	See REPLACING WHEEL HOUSING
	Replacing closing panel	See REPLACING CLOSING PANEL
	Removing vehicle from the alignment bench	Detach side clamping jaws and straightening attachments on the vehicle. Remove vehicle from the alignment bench.
	Cleaning spot-welded joints and sheetmetal flanges with a wire brush	Clean spot-welded joints and sheetmetal flanges with a wire brush. Grind shielding gas weld area visible after installation, apply body solder to connectors to body and align.
	Prime flange areas with 2K primer.
	Restore standard sealing with body sealant.
	Paint exterior outer parts and neighbouring areas.
	Restore standard undersealing protection with permanent undersealing protection agent.
	Supplement cavity preservation.
	Install removed accessories in the repair area.