Preparing Rear Side Panel For Installation

Fit rear side section.

1.1 Cut rear side panel at the point where it joins the side member leaving ai overlap of 30 mm.
1.2 Fit rear side section.
Check gap dimensions.

> 5X00IN41 GAP DIMENSIONS

1.3 Make cuts through the rear side section and body in the overlap areas.

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Rear side section

Drill bore holes for countersunk blind rivets through both sheetmetal panels with > Diameter 4.1 mm .

2.1 Make counter bores for countersunk blind rivets using > VAS 6957 - 100° countersink .

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Countersunk blind rivets

Punch holes for flow-form rivets in areas -A- .
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Flow-form rivets
Drill bore holes for blind rivets -B- through both sheet metal plates using > diameter 6.6 mm .

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Blind rivets
Drill bore holes for blind rivets through both sheet metal plates using > diameter 6.6 mm .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Blind rivets
Punch holes for flow-form rivets in areas -A and B- .
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Flow-form rivets
Drill bore holes for blind rivets -C- through both sheet metal plates using > diameter 6.6 mm .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Blind rivets
Punch holes for flow-form rivets in areas -A and B- .
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Flow-form rivets
Punch holes for flow-form rivets.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Flow-form rivets
Remove rear side section.

Prepare the marked areas for joining.

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Bonding areas

A Bonding and riveting	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00
B Applying a full aluminium weld	> 5X00IN10 WELDING ALUMINIUM

Cut sheetmetal inserts used as a welding backing strip from the old rear side panel.
> 5X00IN10 WELDING ALUMINIUM