Installing Side Section

Information 

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.

1. Installing seal
   1. 1.1. Apply a triangular bead of body sealant Y  measuring dimension "X" = approx. 12 mm  high all around the seal. Position seal on the inside of the side section and press firmly.

      Check dimension for viewing window for inner side section → Length: X = 28 mm 

      Fig 1: Installing Seal Of Body Sealant

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Applying adhesive to the side section
   1. 2.1. Apply a triangular bead of adhesive - dimension "X" = approx. 8 mm - to the inside of the side section, along the wheel arch and up to the start of the sill.
      NOTE: Non-observance of setting time for adhesive

      • Risk of damage to side panel

      → Weld in the new part within 30 minutes.

   2. 2.2.
      Fig 2: Applying Adhesive To Side Section Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Applying adhesive to the inside of the side section
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 3.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the inside of the side section.
      Fig 3: Applying Adhesive To Inside Of Side Section Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Welding in the side section
   Fig 4: Fitting Rear Side Section To Body

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 4.1. Secure the rear side section with tensioning clamps. Use test gauge 9748.
   2. 4.2. Tack-weld the side section at the rear.
      NOTE: Non-observance of setting time for adhesive

      • Risk of damage to side panel

      → Weld in the new part within 30 minutes.

   3. 4.3. Spot-weld area A  of the side panel.
   Fig 5: Identifying Welding Side Panel Area

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Weld in the side panel
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 5.1. Spot weld areas H, F, G, I  of the side panel.
   Fig 6: Identifying Welding Side Section Area (H, F, G And I)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Welding in the side section
   1. 6.1. Spot weld areas B, C, D  of the side section.
   2. 6.2. Weld area E of the side section using inert gas.
   3. 6.3. Plug-weld area P of the side section using inert gas
   Fig 7: Identifying Welding Side Section Area (B, C And D)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Welding in the side section
   1. 7.1. Spot-weld area K  of the side section.
   2. 7.2. Braze weld area J  of the side section.
   Fig 8: Identifying Braze Side Section Area

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8. Welding in the side section
   Fig 9: Identifying Welding Side Section Using Inert Gas

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 8.1. Weld area L of the side section using inert gas.