Installing side section reinforcement

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.

Fig 1: Applying adhesive

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Applying adhesive

1.1. Apply adhesive to the inside of side section reinforcement in the area -A- and -B- in the form of a triangular bead -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 1.

2. Fitting the side section reinforcement to the body

2.1. Fit the side section reinforcement to the body and fix in place with tensioning clamps.

Fig 2: Securing the side section reinforcement

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Securing the side section reinforcement

3.1. Secure the side section reinforcement in the area -A- and -B- with rivets -1- . See Fig 2.

Fig 3: Welding in the side section reinforcement

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Welding in the side section reinforcement

4.1. Resistance spot-weld the side section reinforcement in area -A- and -B- . See Fig 3.

Fig 4: Welding in the side section reinforcement

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in the side section reinforcement

5.1. Plug-weld the side section reinforcement in area -A- using shielding gas. See Fig 4.

Fig 5: Filling out side section reinforcement with foam

Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Filling out side section reinforcement with foam

6.1. Fill out the side section reinforcement with foam through the bore in area -A- 2x, 1 sec. each. See Fig 5.

See: Processing body acoustic foam 2K-AFS Vario. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

7. Install side panel. → 535555 Replacing rear side section - chapter on "Installing"

8. Install outer hinge pillar. → 513755 23 Replacing outer hinge pillar - chapter on "Installing"