Preparing Rear Side Member And Reinforcements For Installation

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Prepare center floor section.
1. 1.1. Make cut according to distance dimensions of old part.
  
  Fig 1: Identifying Centre Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Punch holes for plug welding using inert gas.
  
  Fig 2: Identifying Centre Floor Section Punch Holes For Plug Welding
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Grind both sides of connecting flanges of center floor section in the marked areas until bare.
Prepare wheel housing reinforcement.

Fig 3: Identifying Connecting Flanges Of Centre Floor Section
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 2.1. Drill holes for plug welding using inert gas.
2. 2.2. Grind both sides of connecting flanges of reinforcement in the marked areas until bare.
Prepare rear floor section.

Fig 4: Identifying Connecting Flanges Of Rear Floor Section
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Punch holes for plug welding using inert gas.
2. 3.2. Grind both sides of connecting flanges of rear floor section in the marked areas until bare.
Prepare bulkhead part of center floor side member.

Fig 5: Identifying Bulkhead Part Of Centre Floor Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 4.1. Grind both sides of connecting flanges of bulkhead part in the marked areas until bare.
Information

Procedure for grinding down slots:
1. 10 mm
2. 60 mm
  
  Fig 6: 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.
Prepare rear side member.
1. 5.1. Grind down slots for slot welding.
  
  Fig 7: Identifying Rear Side Member Slot Welding Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Grind down slots for slot welding.
  
  Fig 8: Identifying Rear Side Member Slot Welding
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 5.3. Drill holes for plug welding using inert gas.
4. 5.4. Grind both sides of connecting flanges of rear side member in the marked areas until bare.
  
  Fig 9: Identifying Connecting Flanges Of Rear Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 5.5. Fit and secure bulkhead part on rear side member at dimension -A- .
  → Distance: 100 mm
  
  Fig 10: Identifying Bulkhead Part Dimension On Rear Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 5.6. Resistance spot-weld bulkhead part.
7. 5.7. Spot-weld bulkhead part using inert gas.
Information

Do not apply zinc powder paint to the bonding areas.
Coat all spot-weld flange areas with zinc powder paint.