Removing Side Panel

Fig 1: Side Panel Installation Position Component Location (Except Cayman, Cayman S, Cayman GTS, Boxster GTS)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information 

Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

1. Make cuts. Special electric cutter - fine WE 1137 Pneumatic body saw PS 1 WE 1138 
2. Cut in side panel in the marked areas.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

3. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove side panel.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

6. Drill out spotwelds in the water drain panel area. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Drill out spotwelds in the wheel housing area. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Drill out spotwelds in the hood compartment area. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

9. Make cut in area -A-  . Special electric cutter - fine WE 1137 Pneumatic body saw PS 1 WE 1138 
   1. 9.1. Drill out spotwelds in area -B-  . Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Remove remaining sections of the side panel.

    Information 

    Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

12. Make cut on inner side section. Special electric cutter - fine WE 1137 Pneumatic body saw PS 1 WE 1138 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Drill out the connection point on one side only. Do not damage the plate underneath.

13. Drill out spotwelds on inner side section. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

14. Remove inner section of side panel.
15. Drill out spotwelds on the side panel reinforcement. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Remove side section reinforcement.