Preparing Outer Side Member For Installation

Fit outer side member.
1. 1.1. Cut outer side member at the transitions to the body leaving an overlap of 30 mm.
  
  Fig 1: Preparing Outer Side Member For Installation
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Fit outer side member.
  
  Fig 2: Fitting Outer Side Member For Installation
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Make cuts through the outer side member and body in the overlap areas.
  Check gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS
Remove outer side member.
Make 37 new holes for plug-welding using inert gas using a body hole punch.

Fig 3: Identifying Holes For Plug-Welding
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Prepare connection areas for bonding.

Fig 4: Preparing Outer Side Member For Bonding
Courtesy of PORSCHE CARS NORTH AMERICA, INC.