Installing Rear Side Panel

Information

Do not fit the seal in this area until the adhesive has hardened completely.

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. Tack on sheetmetal insert used as welding backing strip on the body.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Sheetmetal insert

2. Install baffle plate -1-  in rear side panel.
   1. 2.1  Clip baffle plate -1-  into rear side panel.
   2. 2.2  Apply body foam filler -2-  to the baffle plate

      > 5X00IN22 WORKING WITH BODY FOAM FILLER

      Make sure that all openings and gaps are closed off with body foam filler.

      The gap between the inner side panel and rear side panel must be closed when fitting it on the body.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bulkhead part

3. Install rear side panel and check that it fits perfectly.
4. Remove rear side section.
5. Apply adhesive evenly over the marked bonding surface of the body. > Application depth 0.5 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

6. Apply adhesive evenly on the rear side panel in areas -A-  .

   > Application depth 0.5 mm 

   Also apply an adhesive bead of sealant all around the bonding surface. > Application depth 3 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

7. Also apply adhesive in the profile area for the seal for support. > Application depth 6 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Additional adhesive

8. Fit in rear side panel, secure it and check gap dimensions.

   > 5X00IN41 GAP DIMENSIONS

9. Rivet in rear side panel.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   PARTS DESCRIPTION 

   -A-	> FLOW-FORM RIVETS 9A7.008.473.00
   -B-	> BLIND RIVETS 999.190.229.01

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Rivets

10. Rivet in rear side panel. > BLIND RIVET 999.190.227.01 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

11. Rivet in rear side panel.

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    PARTS DESCRIPTION 

    -A-	> FLOW-FORM RIVETS 9A7.008.606.00  .
    -B-	> FLOW-FORM RIVETS 9A7.008.607.00  .
    -C-	> BLIND RIVETS 999.190.227.01

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Rivets

12. Rivet in rear side panel.

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    PARTS DESCRIPTION 

    -A-	> RIVET 9A7.008.606.00
    -B-	> RIVET 9A7.008.607.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Flow-form rivets

13. Rivet in rear side panel.

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    > FLOW-FORM RIVETS 9A7.008.606.00  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Flow-form rivets

14. Rivet in rear side panel.

    > BLIND RIVET PAF.912.885 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Countersunk blind rivets

15. Apply full aluminium weld on rear side panel.

    > 5X00IN10 WELDING ALUMINIUM

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Applying full aluminium weld

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seam

16. Fold over seam in the door aperture using > VAS 6635 - crimping pliers set, 4-piece  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Seam

17. Fold over roll fold in rear wheel arch using > VAS 6635 - crimping pliers set, 4-piece  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Roll fold in rear wheel arch