Preparing Outer Side Member (Front Section) And A-Pillar For Installation

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Cut outer side member (front section) at the transition to the body (B-pillar) leaving an overlap of 30 mm.

Fig 1: Identifying Outer Side Member (Front Section)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Drill holes (Ø 8 mm) for plug welding using inert gas. Maintain spacing between holes as on the old part.

Fig 2: Identifying Outer Side Member (Front Section)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grind both sides of connecting flanges of outer side member in the marked areas until bare.

Fig 3: Identifying Outer Side Member (Front Section)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut A-pillar at the transition to the body (A-pillar) leaving an overlap of 30 mm.

Fig 4: Identifying A-Pillar
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Punch holes (Ø 8 mm) for plug welding using inert gas. Maintain spacing between holes as on the old part.

Fig 5: Identifying Punch Hole On Plug Welding A-Pillar
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grind both sides of connecting flanges of A-pillar in the marked areas until bare.

Fig 6: Identifying Connecting Flanges A-Pillar Punch Hole
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit outer side member and A-pillar.
1. 7.1. Fit outer side member.
2. 7.2. Fit the A-pillar.
3. 7.3. In the area -A, B, C- of the overlaps, make cut through outer side member and A-pillar.
  Observe gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS
  
  Fig 7: Identifying A-Pillar And Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove outer side member and A-pillar.