Removing A-Pillar

Information

Separating the side member involves cutting through the complete side member as well as the support attached to the outside.

Fig 1: A-Pillar Component Location
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Front side section
A-pillar reinforcement
Filler plate for upper carrier

Remove outer side member. → Removing Outer Lower Side Member
Remove lower side member reinforcement. → Removing Lower Side Member Reinforcement

Fig 2: Overview Of Side Member (Outside)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate filler plate section for upper carrier.
Information
- Only the filler plate can be cut through during the separation process. The rear edge of the filler plate on the A-pillar is used as the rear reference line for taking measurements.
1. 3.1. Cut through filler plate for upper carrier in area -A- using the oscillating body saw. Maintain the dimension -X1- → Cut dimension, old part: 130 mm . Do not damage internal components.
  
  Fig 3: Separating Welded Joints On Filler Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Cut the laser-welded joint between the filler plate for the upper carrier and the inner A-pillar using the parting grinder (area -B- ).
3. 3.3. Grind off MIG seams on the A-pillar using a parting grinder (area -C- ).
4. 3.4. Mill off welded joints on the filler plate using the spotweld cutter (areas -A and B- ).
  
  Fig 4: Separating Welded Joints On Filler Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 3.5. Remove filler plate section for upper carrier.
  
  Fig 5: Overview Of Side Member (Outside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate front side section.
Information
- Only the outer panel can be cut through during the separation process. The upper edge of the rectangular opening on the A-pillar is used as the lower reference line for taking measurements.
1. 4.1. Cut through the front side section in area -A- using the oscillating body saw. Maintain the dimension -X2- → Cut dimension, old part: 170 mm . Do not damage internal components.
  
  Fig 6: Separating Welded Joints On Side Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Mill off welded joints on the side section using the spotweld cutter (area -B- ).
3. 4.3. Cut the laser-welded joints between the side section and inner A-pillar using the parting grinder (area -C- ).
4. 4.4. Mill off welded joints on the side section using the spotweld cutter (area -A- ).
  
  Fig 7: Heating Up Sealing And Bonding Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 4.5. Heat up sealing area on the side section uniformly using a hot-air blower (area -B- ).
6. 4.6. Heat up bonding area on the side section uniformly using a hot-air blower (area -C- ).
7. 4.7. Remove front side section.
  
  Fig 8: Overview Of Outer A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off outer A-pillar reinforcement.
1. 5.1. Mill off welded joints on the A-pillar reinforcement using the spotweld cutter (areas -A and B- ).
  
  Fig 9: Separating Welded Joints On A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Cut the laser-welded joints between the A-pillar reinforcement and inner A-pillar using the parting grinder (areas -C, D and E- ).
  
  Fig 10: Overview Of Side Member (Inside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off inner A-pillar reinforcement.
1. 6.1. Grind off MIG seams on the inner A-pillar using a parting grinder (area -A- ).
  
  Fig 11: Separating Welded Joints On Inner A-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 12: Overview Of Outer A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release A-pillar reinforcement.
1. 7.1. Heat up sealing area on the outer A-pillar reinforcement uniformly using a hot-air blower (area -A- ).
  
  Fig 13: Heating Up Sealing Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Heat up the seal on the A-pillar reinforcement uniformly starting from the inside of the vehicle using a hot-air blower (area -B- ).
Remove A-pillar reinforcement and seal.