Preparing Outer Side Member (Cabriolet) 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 (Cabriolet) -A-  at the joints to the body and cut it to size.
   2. 1.2  Fit in outer side member (Cabriolet) -A-  and secure it.
   3. 1.3  Cut through the outer side member (Cabriolet) and body in the overlap area -A-  .

      Check gap dimensions.

      > 5X00IN41 GAP DIMENSIONS

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Cut on outer side member (Cabriolet)

2. Drill bore holes for blind rivets in areas -A-  through both sheetmetal plates with > Diameter 6.6 mm  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   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 counterbores at rivet holes using > VAS 6957 - 100° countersink  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bore holes

4. Drill holes for self-tapping screws through the existing holes with > Diameter 4 mm  .

   > 5X00IN24 SETTING SELF-TAPPING SCREWS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Outer side member (Cabriolet)

5. Remove outer side member (Cabriolet).
6. Cut sheetmetal inserts used as a welding backing strip for the weld area from the old outer side member (Cabriolet).
7. Prepare marked areas of the outer side member (Cabriolet) for joining.
8. Prepare steel adapter for applying a full weld using inert gas.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   PARTS DESCRIPTION 

   A	Bonding and riveting.
   	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00
   B	Aluminium welding
   	> 5X00IN05 INFORMATION ON ALUMINIUM REPAIRS
   C	Applying full weld using inert gas.