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Home >> Porsche >> 2006 >> Cayman Standard >> 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) >> Removing Outer Lower Side Member

Removing Outer Lower Side Member

Fig 1: Outer Lower Side Member Component Location
GP00011421Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fig 2: Determining the cut
GP00011422Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Determining the cut

1.1. Position separation point -A-  so that the spare part for the outer side member overlaps by approx. 40 mm. Mark the separation point. See Fig 2.

1.2. Position separation point -B-  so that the spare part for the outer side member overlaps by approx. 60 mm. Mark the separation point. See Fig 2.

Fig 3: Cutting through outer lower side member
GP00011423Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Cutting through outer side member

2.1. Cut through the outer side member at the marked connection point -A-  using the oscillating body saw. Do not damage the internal components while doing so. See Fig 3.

2.2. Cut through the outer side member at the marked connection point -B-  using the oscillating body saw. Do not damage the internal components while doing so. See Fig 3.

Fig 4: Milling off spotwelds
GP00011424Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Milling off spotwelds

3.1. Mill off spotwelds in area -A-  using a spotweld cutter. See Fig 4.

Fig 5: Milling off spotwelds
GP00011425Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Milling off spotwelds

4.1. Mill off spotwelds in area -A-  using a spotweld cutter. See Fig 5.

Fig 6: Separating spotwelds
GP00011426Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Separating spotwelds

5.1. Separate spotwelds in area -A-  using a parting grinder. See Fig 6.

Fig 7: Cutting the web plate
GP00011427Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Cutting the web plate

6.1. Cut through the separator in areas -A, B, C-  using the body saw. See Fig 7.

Fig 8: Milling off the web plate
GP00011428Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Milling off the web plate

7.1. Mill off separator in area -A-  using a spotweld cutter. See Fig 8.

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