Installing Side Section

→ Weld in the new part within 30 minutes.

1. Installing seal
   1. 1.1. Apply a triangular bead of body sealant 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 -Y = 20 mm-  with respect to roof reinforcement.

   Fig 1: Installing Seal Of Side Section

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Apply adhesive on the inside of the side section
   1. 2.1. Apply a triangular bead of Betamate 2096  adhesive measuring -dimension X = approx. 8 mm-  in height to the joint between the light housing and the inside of the side section. The light frame must lie flush with the inside of the side section.
   Fig 2: Applying Adhesive To Inside Of Side Section

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Apply adhesive to the side section
   1. 3.1. Apply a triangular bead of adhesive (Teromix-6700) measuring -dimension X = approx. 8 mm-  to the inside of the side section, along the wheel arch up as far as the start of the door sill.
   Fig 3: Applying Adhesive To Side Section

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Determine the position of the new part and secure with tensioning clamps.

   When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

4. Fit the side section to the body
   1. 4.1. Secure the side section with tensioning clamps. Use test gauge 9748  .
   2. 4.2. Tack-weld the side section.
   Fig 4: Fitting Side Section To Body

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Weld in the side section
   1. 5.1. Resistance spot-weld the side panel in area -A-  .
   Fig 5: Identifying Welding Side Section Area

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Weld in the side section
   1. 6.1. Resistance spot-weld the side panel in area -A-  .
   Fig 6: Identifying Spot-Weld Side Panel Area

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Weld in the side section
   1. 7.1. Resistance spot-weld the side panel in area -A-  .
   Fig 7: Identifying Spot-Weld Side Panel Area (A)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   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.

8. Weld in the side section
   1. 8.1. Resistance spot-weld the side panel in area -A-  .
   Fig 8: Identifying Welding Side Section Area (A)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Weld in the side section
   1. 9.1. Resistance spot-weld the side panel in area -A-  .
   Fig 9: Identifying Welding Side Section Area (A)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Weld in the side section
    1. 10.1. Resistance spot-weld the side section in area -A, B, C, D, E-  .
    Fig 10: Identifying Welding Side Section Area (A, B, C, D And E)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Weld in the side section
    1. 11.1. Resistance spot-weld the side section in areas -A-  and -B-  .
    Fig 11: Identifying Welding Side Section Area (A And B)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Weld in the side section
    1. 12.1. Resistance spot-weld the side section in areas -A-  and -C-  .
    2. 12.2. Plug-weld the side section in area -B-  using inert gas.
    Fig 12: Identifying Welding Side Section Area (B)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Weld in the side section
    1. 13.1. Resistance spot-weld the side panel in area -A-  .
    Fig 13: Identifying Welding Side Section Area (A)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Weld in the side section
    1. 14.1. Plug-weld the side section in area -A-  using inert gas.
    Fig 14: Identifying Welding Side Section Area (A)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Weld in the side section
    1. 15.1. Apply a full weld to the side section in area -A-  using inert gas.
    Fig 15: Identifying Welding Side Section Area (A)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
16. Weld in the side section
    1. 16.1. Apply a full weld to the side section in area -A-  using inert gas.
    Fig 16: Identifying Welding Side Section Area

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.