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Home >> Porsche >> 2005 >> Boxster S, Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN >> 53 62 55 Replacing Frame For Light (Section) - As Of My 2006 (CAYMAN S, CAYMAN S RHD) >> Installing Frame For Light (Section) >> Installing light frame (section)

Installing light frame (section)

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).

1. Fitting light frame to the body

1.1. Fit the light frame to the body and fix in place with tensioning clamps.

1.2. To complete the fit, install the rear light and set the gap clearance between the rear light and side panel according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

2. Welding in light frame

2.1. Tack-weld the light frame and remove rear light.

Fig 1: Welding in light frame
GP00011962Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Welding in light frame

3.1. Resistance spot-weld the light frame in area -A, B, C, D-  . See Fig 1.

Fig 2: Welding in light frame
GP00011963Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Welding in light frame

4.1. Plug-weld the light frame in the areas -A, B, C-  under shielding gas. See Fig 2.

Fig 3: Welding in light frame
GP00011964Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in light frame

5.1. Plug-weld the light frame in the areas -A-  and -B-  under shielding gas. See Fig 3.

Fig 4: Welding in light frame
GP00011965Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Welding in light frame

6.1. Apply a full weld the light frame in the areas -A-  and -B-  using shielding gas. See Fig 4.

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