Removing Front Side Member

Fig 1: Front Side Member Component Location (Section)

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Front Side Member

1. Roughly Cut Out Longitudinal Member -1-  And Longitudinal Member For Wheel Housing -2-  .
   IMPORTANT: The Final Dimension Is Measured From The New Front Side Member (Section).
   1. 1.1  Cut Longitudinal Member To Dimension -X-  . > Length 180 Mm 
      Fig 2: Checking Longitudinal Member Cutting Dimension

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      Roughly Cutting Longitudinal Member

      Dimension -X-  Is Measured From The Bent Edge To The Reinforcement -3-  .

      Mark And Make Cut. > Length 125 Mm 

      Remove Remaining Piece

      Fig 3: Checking Inner Longitudinal Member Cutting Dimension

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      Connection Point For Inner Longitudinal Member

   2. 1.2  Drill Through Punch Rivets Using A > Nr.201 - Twist Drill  .

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      Removing Side Member

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      Removing Side Member

      IMPORTANT: Only Make Cuts In The Top Plate. Make Sure Not To Damage The Plate Underneath When Doing This.
   3. 1.3  Cut Outer Shell To Dimension -Y-  . > Length 100 Mm 

      Drill Through Punch Rivets Using > Nr.201 - Twist Drill  .

      Fig 4: Checking Outer Shell Cutting Dimension

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      Cut On Outer Shell Of Longitudinal Member

      1. 1.3.1  Heat Bonding Areas > Removing Outer Shell  . > V.A.G 1416 - Hot-Air Blower 
   4. 1.4  Remove Remaining Part Of Outer Shell.
      Fig 5: Checking Outer Shell Cutting Dimension

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      Removing Outer Shell

   5. 1.5  Mark Cut On Inner Shell In Accordance With The New Part With Slight Oversize.
      IMPORTANT: Only Make Cuts In The Top Plate. Make Sure Not To Damage The Plate Underneath When Doing This.
   6. 1.6  Cut Inner Shell. Be Careful Of Inner Panels On The Underside -Arrow-  .

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      Inner Shell Cut

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      Lower Inner Shell Cut

2. Remove Remaining Part Of Wheel Housing
   1. 2.1  Heat Bonding Areas. > V.A.G 1416 - Hot-Air Blower 

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      Bonding Areas

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      Bonding Area

   2. 2.2  Remove Remaining Part Of Wheel Housing.
3. Fit Sub-Part Exactly Using The Straightening Set. Shorten Side Member On The Vehicle As Required.