Preparing Outer Side Member For Installation: Notes

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Fit outer side member.

Fig 1: Preparing Outer Side Member For Installation
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Cut outer side member at the transitions to the body leaving an overlap of 30 mm.
2. 1.2. Fit outer side member.
  Observe gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS
  
  Fig 2: Identifying Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Make cuts through the outer side member and body in the overlap areas.
Remove outer side member.
Drill holes for plug welding using inert gas.
In the area of the A-pillar, maintain spacing between the holes as on the old part.

→ Distance to upper edge: 10 mm

Fig 3: Identifying Drill Holes For Plug Welding Outer Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grind both sides of connecting flanges of outer side member in the marked areas until bare.

Fig 4: Identifying Outer Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.