Preparing Side Section Rear For Installation

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

1. Fit in side section rear.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Cut A

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Cut B

   1. 1.1 Mark and cut side section rear at the points where it joins the body.
   2. 1.2 Fit side section rear and secure it to the body.

      > 5X00IN GAP DIMENSION

      Information 

      Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 30 mm with respect to the body.

   3. 1.3 Make cuts -A-  and -B-  through the side section rear and body in the overlap areas.
2. Cut sheetmetal insert used as a welding backing strip for the welding areas from the old side section rear.
3. Drill bore hole for blind rivet -2-  through both sheetmetal plates using > Diameter 6.6 mm  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint connections

4. Drill bore holes for blind rivets through both sheetmetal panels using > Diameter 6.6 mm  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

5. Drill hole for countersunk blind rivet through both panels using > Diameter 6.5 mm  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivet

   1. 5.1 Make counterbore at the rivet hole using > VAS 6957 - 100° countersink. 
6. Punch holes for flow-form rivets.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Flow-form rivets

7. Prepare joints in the rear lid area.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joints

   1. 7.1 Drill bore holes for blind rivets -A-  through both sheetmetal panels using > Diameter 6.6 mm  .
   2. 7.2 Punch holes for flow-form rivets -B-  .
8. Prepare joints in the rear window area.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joints

   1. 8.1 Punch holes for flow-form rivets -A-  .
   2. 8.2 Drill the hole for the countersunk blind rivet -B-  through both sheets using > Diameter of 4.1 mm  .
   3. 8.3 Make counterbore at the rivet hole -B-  using > VAS 6957 - 100° countersink. 

   Information 

   If the wheel housing has also been replaced on the outside, mark the hole from the outside with the aid of the retaining frame for the rear bumper and drill through both components when installed.

9. Mark the hole for the blind rivet nut from the inside through the inner wheel housing -2-  on the side section rear -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivet nut hole

10. Remove side section rear.
11. Drill through a hole for the blind rivet nut using > Diameter 9 mm  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivet nut hole

12. Prepare side section rear for bonding and riveting.

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

13. Prepare side section rear for joining.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Joint areas

    1. 13.1 Prepare side section rear in areas -A-  for bonding and riveting.

       > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    2. 13.2 Prepare side section rear in areas -B-  for aluminium welding.

       > 5X00IN10 WELDING ALUMINIUM