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Home >> Porsche >> 2016 >> Boxster Spyder >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 51 - Body Center, Roof, Frame - BOXSTER & CAYMAN >> WM 511355 Replacing A-Pillar Reinforcement (CAYMAN, CAYMAN S) >> Preparing A-Pillar Reinforcement

Preparing A-Pillar Reinforcement

  1. Cut new part.
    1. 1.1. Make a rough cut through the complete reinforcement.
      G10029071Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Only make a cut through the outer panel -2-  .

    Information 

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

    1. 2.1. Mark and make cut. → Distance: 40 mm 
    2. 2.2. Drill out spotwelds -3-  using spotweld drill  .
    3. 2.3. Remove remaining piece -2-  .
      G10029072Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Prepare A-pillar reinforcement -1-  for installation.

    Information 

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

    1. 3.1. Drill out spotwelds -3-  using spotweld drill  .
    2. 3.2. Remove remaining piece -2-  .
      G10029073Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Fit in new part and secure it to the body. Check gap dimensions. → 5X00IN41 GAP DIMENSIONS
    1. 4.1. Cut new part -1-  .
    2. 4.2. Drill holes for rivets in area -2-  using → Diameter: 6.6 mm  .
      G10029074Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Prepare connection areas for bonding and welding.
    G10029075Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Blue Resistance spot-welding + bonding
    Magenta Bonding + riveting
    Orange Bonding
    Red Plug-welding/apply a full weld using inert gas without bonding


  1. Cut new part.
    1. 1.1. Make a rough cut through the complete reinforcement.
      G10029098Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Only make a cut through the outer panel -2-  .

    Information 

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

    1. 2.1. Mark and make cut. → Distance: 40 mm 
    2. 2.2. Drill out spotwelds -3-  using spotweld drill  .
    3. 2.3. Remove remaining piece -2-  .
      G10029099Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Prepare A-pillar reinforcement -1-  for installation.

    Information 

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

    1. 3.1. Drill out spotwelds -3-  using spotweld drill  .
    2. 3.2. Remove remaining piece -2-  .
      G10029100Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Fit in new part and secure it to the body. Check gap dimensions. → 5X00IN41 GAP DIMENSIONS
    1. 4.1. Cut new part -1-  .
    2. 4.2. Drill holes for rivets in area -2-  using → Diameter: 6.6 mm  .
      G10029101Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Prepare connection areas for bonding and welding.
    G10029102Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Blue Resistance spot-welding + bonding
    Magenta Bonding + riveting
    Orange Bonding
    Red Plug-welding/apply a full weld using inert gas without bonding
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