Preparing Gusset Plate

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. Fit and secure the gusset plate.
2. Prepare joints.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Inner joints

   1. 2.1  Drill holes for rivets at the points -A-  . > Diameter 6.6 mm 
   2. 2.2  Drill at points -B-  using the pilot hole for rivets. D > diameter 6.6 mm 
   3. 2.3  Set pilot bores for self-tapping screws at points -1-  . > Diameter 3.5 mm 

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

3. Prepare joints.

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   Longitudinal member area

   1. 3.1  Drill a hole for rivet at point -A-  . > Diameter 6.6 mm 
   2. 3.2  Drill holes for rivets at the points -B-  . > Diameter 6.6 mm 
   3. 3.3  Place pilot bores for self-tapping screws at the positions -1-  . > Diameter 3.5 mm 

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

4. Prepare joints.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Underbody joints

   1. 4.1  Drill holes for rivets at the points -A-  . > Diameter 6.6 mm 
   2. 4.2  Drill holes for rivets at the points -B-  . > Diameter 6.6 mm 
   3. 4.3  Drill -C-  a hole for rivet according to the specified  dimensions at the point. > diameter 6.6 mm 

      > Length 11 mm 

      > Length 16.5 mm 

   4. 4.4  Set the pilot bore for self-tapping screws at this point -1-  > Diameter 3.5 mm 

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

5. Remove gusset plate.
6. Prep are the marked areas for bonding and riveting.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas