Repairing The Side Panel

→ Wear personal protective gear.

Information 

Separation of the sheetmetal panel depends on the extent of the damage.

1. Cut out the side panel (old part)
   1. 1.1. Place outer cut flush with the inner edge of the door gap and mark the cut.
      Fig 1: Identifying Cut Marking

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 1.2. Mark the cut at the top and bottom at -dimension X= 75 mm-  .
   3. 1.3. Remove spotwelds in area -A-  using a spotweld cutter.
      Fig 2: Cutting Side Panel

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   4. 1.4. Cut through the side panel at the marked separation points -B, C, D-  using the oscillating body saw.
   WARNING: Grinding and welding work

   • Danger of fire or explosion

   → Avoid working in an area with highly inflammable or explosive materials.

   → Cover highly inflammable or explosive areas.

   → Remove highly inflammable or explosive parts.

2. Prepare connection areas of body for installing the side panel
   1. 2.1. Remove paint from the body connection flanges in the marked areas -A, B, C, D-  using a hot-air gun or rotary brush. Grind the connection flanges until bare.
      Fig 3: Preparing Connection Areas

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit the side panel (new sub-part) and prepare for installation
   1. 3.1. Mark the sub-part so that there is approx. 30 mm overlap at the joints.
      Fig 4: Preparing Sub-Part

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 3.2. Cut the sub-part at the marked areas -A, B, C-  .
   3. 3.3. To fit, position the sub-part at the connecting flanges, secure it and mark it all the way around from inside using a scriber.
      Fig 5: Preparing Sub-Part At Marked Areas

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   4. 3.4. Cut the sub-part according to the crack and grind the connecting flanges -A, B, C, D-  until bare.
   5. 3.5. Coat spot-weld flange areas with zinc powder paint.
   WARNING: Electric welding

   • Risk of electric shock or burns

   → Wear personal protective gear.

   → Disconnect both battery terminals.

   → Do not weld in a damp area or when it is wet under foot.

   → Move highly inflammable materials out of the work area. Ventilate the work area well.

   → Remove smoke gases with an extraction system.

   → Read specific safety information for the welder.

   → Check that welder is working perfectly before use.

4. Weld in the side section (sub-part)
   1. 4.1. Fit the sub-part to the body, fix it in place and tack-weld it.
      Fig 6: Identifying Installing Sub-Part

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 4.2. Resistance spot-weld the sub-part in area -A-  .
   3. 4.3. Apply a full weld to the sub-part in areas -B, C, D-  using inert gas.