LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2016 >> Boxster S, Automatic DCT Trans >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN (981) >> WM 535555 Replacing Side Panel (Except CAYMAN, CAYMAN S, CAYMAN GTS, BOXSTER GTS) >> Preparing Side Panel For Installation

Preparing Side Panel For Installation

  1. Prepare connection areas for welding and bonding.

    Information 

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

  2. Make cuts. Special electric cutter - fine WE 1137 Pneumatic body saw PS 1 WE 1138 
  3. Loosen the sheetmetal part as shown using a cut from the new part.
    G10023386Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Magenta Resistance spot-welding + bonding
    Red Plug-welding (inert gas)/apply a full weld using inert gas without bonding
    Yellow Riveting + bonding
    Blue Bonding
  4. Prepare connection areas for welding and bonding.
    G10023387Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    G10023388Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    G10023389Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Close off cavities on the inside in the hood compartment area using seam seal.
    G10023390Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Prepare wheel housing at the connection areas for bonding and welding.
    1. 6.1. Drill holes in area for plug welding using a drill bit with a diameter of → Diameter: 8.0 mm  Drill bit Ø.
      G10023391Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Drill holes for plug welding in the marked areas -B -  using a drill bit with a diameter of → Diameter: 8.0 mm  Drill bit Ø.
    G10023392Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Orange Resistance spot-welding + bonding
    Red Plug-welding (inert gas)/apply a full weld using inert gas without bonding