Removing Front Side Member

Fig 1: Identifying Front Side Member

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Roughly cut out longitudinal member -1- and longitudinal member for wheel housing -2- .
1. 1.1. Cut longitudinal member to dimension -X- . → Length: 180 mm
  
  Fig 2: Identifying Longitudinal Member Cutting Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Dimension -X- is measured from the bent edge to the reinforcement -3- .
  
  Information
  
  The final dimension is measured from the new front side member (section).
  
  Mark and make cut. → Length: 125 mm
  
  Remove remaining piece -1- .
  
  Fig 3: Identifying Inner Longitudinal Member Connection Point
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Drill through punch rivets using a twist drill Nr.201 .
  
  Fig 4: Removing Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 5: Identifying Side Member
  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.
3. 1.3. Cut outer shell to dimension -Y- . → Length: 100 mm
  Drill through punch rivets using twist drill Nr.201 .
  
  Fig 6: Locating Longitudinal Member Outer Shell
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.3.1. Heat bonding areas → Removing outer shell . Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
4. 1.4. Remove remaining part of outer shell.
  
  Fig 7: Removing Outer Shell
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Mark cut on inner shell in accordance with the new part with slight oversize.
  Information
  
  Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.
6. 1.6. Cut inner shell. Be careful of inner panels on the underside -arrow- .
  
  Fig 8: Identifying Front Side Member Inner Shell Cut
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 9: Locating Lower Inner Shell Cut
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove remaining part of wheel housing
1. 2.1. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
  
  Fig 10: Identifying Front Side Member Bonding Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 11: Identifying Front Side Member Bonding Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Remove remaining part of wheel housing.
Fit sub-part exactly using the straightening set. Shorten side member on the vehicle as required.