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Home >> Porsche >> 2006 >> Boxster S, Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN >> 53 48 55 Replacing Rear Side Member - As Of My 2005 (All Models) >> Removing Rear Side Member >> Removing rear side member

Removing rear side member

Fig 1: Determining the cut
GP00011706Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Determining the cut

1.1. Determine the position of the cut in area -A-  at dimension -X= approx. 200 mm-  . Mark the cut. See Fig 1.

Fig 2: Cutting through rear side member
GP00011707Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Cutting through outer rear side member

2.1. Cut through the outer rear side member in area -A-  . See Fig 2.

Fig 3: Milling off spotwelds
GP00011708Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Milling off spotwelds

3.1. Mill off spotwelds in areas -A, B, C-  using a spotweld cutter. See Fig 3.

Fig 4: Milling off spotwelds
GP00011709Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Milling off spotwelds

4.1. Mill off spotwelds in areas -A-  and -B-  using a spotweld cutter. See Fig 4.

Fig 5: Milling off spotwelds
GP00011710Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Milling off spotwelds

5.1. Mill off spotwelds in areas -A-  and -B-  using a spotweld cutter. See Fig 5.

Fig 6: Milling off spotweld
GP00011711Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Milling off spotweld

6.1. Mill off spotweld in area -A-  using a spotweld cutter. See Fig 6.

Fig 7: Milling off spotwelds
GP00011712Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Milling off spotwelds

7.1. Mill off spotwelds in areas -A, B, C, D-  using a spotweld cutter. See Fig 7.

7.2. Mill off spotweld in area -E-  using a spotweld cutter (2 plate thicknesses). See Fig 7.

Fig 8: Milling off spotwelds
GP00011713Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Milling off spotwelds

8.1. Mill off spotwelds in areas -A, B, C-  using a spotweld cutter. See Fig 8.

Fig 9: Milling off spotweld
GP00011714Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Milling off spotweld

9.1. Mill off spotweld in area -A-  using a spotweld cutter. See Fig 9.

Fig 10: Separating welded joints
GP00011715Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Separating welded joints

10.1. Separate inert-gas welded seam in area -A-  using a parting grinder. See Fig 10.

10.2. Separate spotwelds in area -B-  using a parting grinder. See Fig 10.