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Home >> Porsche >> 2006 >> Cayman Automatic >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 51 - Body Center, Roof, Frame- BOXSTER & CAYMAN >> 51 45 55 Replacing Outer Lower Side Member - As Of My 2006 (CAYMAN S, CAYMAN S RHD) >> Installing Outer Lower Side Member >> Installing Outer Lower Side Member

Installing Outer Lower Side Member

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).
Fig 1: Fitting in outer lower side member on the body
GP00011430Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Fitting in lower side member on the body

1.1. To complete the fit, install the doors and wings at the front and set the gap dimensions between the door at the rear and the front wing according to the respective adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1.2. Fix the outer side member to the body with tensioning clamps.

WARNING: Welding in body components 
  • Danger of injury and material damage 

→ Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide area. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Fig 2: Weld in outer lower side member
GP00011434Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Welding in outer lower side member

2.1. Resistance spot-weld outer side member in the area -A-  . See Fig 2.

Fig 3: Weld in outer lower side member
GP00011435Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Welding in outer lower side member

3.1. Resistance spot-weld outer side member in the area -A-  . See Fig 3.

Fig 4: Weld in outer lower side member
GP00011436Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Welding in outer lower side member

4.1. Resistance spot-weld outer side member in the area -A-  . See Fig 4.

Fig 5: Weld in outer lower side member
GP00011437Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in outer lower side member

5.1. Plug-weld the side member in area -A-  under shielding gas. See Fig 5.

Fig 6: Weld in outer lower side member
GP00011438Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Welding in outer lower side member

6.1. Apply a full weld the side member in the areas -A-  and -B-  using shielding gas. See Fig 6.

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