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Home >> Porsche >> 2006 >> Boxster S, Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN >> 53 61 55 Replacing Inner Side Section - As Of My 2006 (CAYMAN S, CAYMAN S RHD) >> Installing Inner Side Section >> Installing front inner side section

Installing front inner side section

WARNING: Traffic safety warning for bonding structural components with structural adhesive! 
  • Danger of material damage and injury 

→ Join, fix and resistance spot-weld parts within the processing time. The jointing operation must take place directly after application of the adhesive in order to guarantee high-quality and reliable bonding. Otherwise the adhesive bead must be removed and pre-treatment of the surface and application of the adhesive must be repeated.

→ To ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.

→ Process the adhesive within the processing time. The adhesive must be applied and the body part must be jointed within this period. Any resistance welding to be carried out in the area of the bonding must be performed within this period as well. → Processing time: 60 min

→ Do not apply pressure to bonded parts until hardening is complete!

→ If the contents of the cartridge is not used up completely, the processing nozzle must be kept on the cartridge until the adhesive hardens. If you intend to use the adhesive again later, a new processing nozzle must be used.

1. Fitting bracket for side section and front inner side section to the body

1.1. Fit bracket for side section and front inner side section to the body, check them and fix in place with tensioning clamps.

Fig 1: Marking the bonding area
GP00011951Courtesy of PORSCHE OF NORTH AMERICA, INC.

1.2. Mark front inner side section in the bonding area -A-  with a scriber. See Fig 1.

1.3. Remove front inner side section.

Fig 2: Welding in bracket for side section
GP00011936Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Welding in bracket for side section

2.1. Apply a full weld to the side section bracket in area -A-  using inert gas. See Fig 2.

Fig 3: Welding in bracket for side section
GP00011937Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Welding in bracket for side section

3.1. Apply a full weld to the side section bracket in area -A-  using inert gas. See Fig 3.

Fig 4: Applying adhesive
GP00011938Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Applying adhesive

4.1. Using the bonding gun, apply structural adhesive to the front inner side section in the marked area -A-  in the form of a triangular bead measuring -dimension X = approx. 3 mm-  . See: Working with body structural adhesive Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) . See Fig 4.

5. Fitting the front inner side section to the body

5.1. Fit the front inner side section to the body and fix in place with tensioning clamps.

Fig 5: Securing front inner side section
GP00011939Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Securing front inner side section

6.1. Secure front inner side section in areas -A-  and -B-  with rivets -1-  . See Fig 5.

Fig 6: Welding in front inner side section
GP00011940Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Welding in front inner side section

7.1. Resistance spot-weld the front inner side section in area -A-  . See Fig 6.

Fig 7: Welding in front inner side section
GP00011941Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Welding in front inner side section

8.1. Resistance spot-weld the front inner side section in area -A-  . See Fig 7.

Fig 8: Welding in front inner side section
GP00011942Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Welding in front inner side section

9.1. Resistance spot-weld the front inner side section in areas -A, B, C-  . See Fig 8.

Fig 9: Welding in front inner side section
GP00011943Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Welding in front inner side section

10.1. Resistance spot-weld the front inner side section in area -A-  . See Fig 9.

Fig 10: Welding in front inner side section
GP00011944Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Welding in front inner side section

11.1. Plug-weld the front inner side section in area -A-  using inert gas. See Fig 10.

11.2. Resistance spot-weld the front inner side section in areas -B-  and -C-  . See Fig 10.

Fig 11: Welding in front inner side section
GP00011945Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Welding in front inner side section

12.1. Plug-weld the front inner side section in area -A-  using inert gas. See Fig 11.

Fig 12: Welding in front inner side section
GP00011946Courtesy of PORSCHE OF NORTH AMERICA, INC.

13. Welding in front inner side section

13.1. Plug-weld the front inner side section in area -A-  using inert gas. See Fig 12.

Fig 13: Welding in front inner side section
GP00011947Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Welding in front inner side section

14.1. Plug-weld the front inner side section in areas -A-  and -B -  using inert gas. See Fig 13.

Fig 14: Welding in front inner side section
GP00011948Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Welding in front inner side section

15.1. Apply a full weld to the front inner side section in area -A-  using inert gas. See Fig 14.

16. Install center side member. → 514855 23 Replacing center side member - section on "Installing" 

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