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Preparing Rear Side Section For Installation (Roof Removed)

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  1. Fit rear side section.
    1. 1.1. Cut rear side section at the transitions to the body leaving an overlap of 30 mm.
      Fig 1: Identifying Rear Side Section For Installation (Roof Removed)
      G09939120Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 1.2. Fit rear side section.

      Observe gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS

      Fig 2: Identifying Rear Side Section Body Gap Dimensions
      G09939121Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 1.3. Make cuts through the rear side section and body in the overlap areas.
  2. Make holes for plug welding using inert gas with a body hole punch.
    Fig 3: Identifying Holes For Plug Welding On Rear Side Section
    G09939122Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Grind both sides of the connecting flanges of the rear side section in the marked areas until bare.
    Fig 4: Identifying Connecting Flanges Of Rear Side Section
    G09939123Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Do not apply zinc powder paint to the bonding areas.

  4. Coat all spot-weld flange areas with zinc powder paint.