Preparing Front Side Member For Installation

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Drill out spotwelds using spotweld drill bit and remove plenum panel closing element.
Drill out spotwelds so that no holes are made in the new part.

Fig 1: Identifying Front Side Member Drill Out Spotwelds
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Drill holes (Ø 10 mm) for plug welding using inert gas.

Fig 2: Identifying Front Side Member Drill Holes For Plug Welding
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut/shorten sheetmetal lugs in marked area -A- using the body saw.
Information

Procedure for grinding down slots:
1. 10 mm
2. 60 mm
  
  Fig 3: Identifying Grinding Down Slots
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- Mark slot to the dimension -A- and -B- .
- Drill through the end points using a Ø 10 mm drill bit.
- Grind down connecting line from hole to hole using a parting grinder.
Grind down slots for slot welding.

Fig 4: Identifying Grind Down Slots For Slot Welding On Front Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grind both sides of connecting flanges of front side member in the marked areas until bare.

Fig 5: Identifying Connecting Flanges Of Front Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Coat all spot-weld flange areas with zinc powder paint.