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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 514555 Replacing Outer Side Member >> Installing Side Member

Installing Side Member

Information 

  1. Apply adhesive. → Application depth: 3.0 mm 

    Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

    G10029181Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Resistance spot-weld the side member.
    1. 2.1. Rivet in area -B-  . → BLIND RIVET 999.190.227.01
      G10029182Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Resistance spot-weld the side member.
    1. 3.1. Rivet in area -A-  . → BLIND RIVET 999.190.227.01
      G10029183Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Information 

      • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
      • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
      • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
  4. Apply adhesive. → Application depth: 3.0 mm 

    Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

    G10029184Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Rivet in B-pillar section.
    G10029185Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 5.1. Rivet in B-pillar section in areas -B, C-  . → BLIND RIVET 999.190.227.01
    2. 5.2. Resistance spot-weld the B-pillar section in area -A-  .
    3. 5.3. Apply a full weld to the B-pillar section in area -D-  .
  6. Apply a full weld to the B-pillar section in areas -X-  using inert gas.
    G10029186Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Cut new inner side section in accordance with the measurements and the old part.
    G10029187Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Prepare inner side panel section for bonding.

    Information 

    • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
    • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
    • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
    1. 8.1. Apply adhesive. → Application depth: 3.0 mm 

      Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE .

      G10029188Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Install inner side panel section.
    1. 9.1. Resistance spot-weld area -A-  .
    2. 9.2. Apply a full weld to area -X-  using inert gas.
      G10029189Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Resistance spot-weld the side member in the rear closing panel area
    G10029190Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Yellow Resistance spot-welding + bonding

    Information 

    • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
    • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
    • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
  11. Cut new outer side section in accordance with the measurements and the old part.
    1. 12.1. Prepare new part for bonding.

      Information 

      • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
      • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
      • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
    2. 12.2. Apply adhesive. → Application depth: 3.0 mm 

      Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE .

  13. Install outer side panel section.
    1. 13.1. Resistance spot-weld the side panel section in area -A-  carefully.
    2. 13.2. Plug-weld the side panel section in area -B-  carefully.
      G10029191Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Apply a full weld to the side panel section in area -X-  using inert gas.
    G10029192Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Install A-pillar section.
    1. 15.1. Plug-weld areas -B and C-  carefully.
    2. 15.2. Apply a full weld to area -X-  using inert gas.
      G10029193Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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