Preparing Outer Side Member (Coupe) For Installation

Information 

Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

1. Cut spare part to size.

   Information 

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

   1. 1.1  Mark outer side member (Coupe) at the joints to the body and cut it to size.
   2. 1.2  Fit and secure outer side member (Coupe).
   3. 1.3  Make cuts through the outer side member and body in the overlap area -A-  .

      Check gap dimensions.

      > 5X00IN41 GAP DIMENSIONS

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Outer lower side member (Coupe)

2. Drill holes for blind rivets in areas -A-  through both sheet metal panels with > diameter 6.6 mm  .

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   Bore holes

3. Drill bore holes for countersunk rivets through the existing holes in areas -B-  and -C-  with > diameter 6.5 mm  .
   1. 3.1  Make counter bores on rivet holes using > VAS 6957 - 100° countersink  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bore holes

4. Remove outer side member (Coupe).
5. Cut sheetmetal inserts used as a welding backing strip for the weld area from the old outer side member (Coupe).
6. prepare outer marked areas of the lower side member (Coupe).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

   1. Bonding and riveting.

      > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   2. Applying full aluminium weld.

      > 5X00IN10 WELDING ALUMINIUM

   3. Applying full weld using inert gas.