Installing Outer Roof Rail

Information 

Make sure that no joint areas/joints are sticking out.

1. Tack on sheet metal insert > Sheet metal insert  used as a welding backing strip on the body.

   > 5X00IN10 WELDING ALUMINIUM

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   Sheet metal insert

   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. 
2. Apply adhesive. > Bonding and rivet areas  > Application depth 3.0 mm  Work with body structural adhesive.

   > 5X00IN21 WORK WITH BODY STRUCTURAL ADHESIVE

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   Bonding and rivet areas

   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 operators is guaranteed. 
   • Do not begin bonding work until all materials and tools necessary for later repair work are available. 
3. Apply adhesive. > Connection areas of body  > Application depth 3.0 mm  Work with body structural adhesive.

   > 5X00IN21 WORK WITH BODY STRUCTURAL ADHESIVE

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   Connection areas of body

4. Fit and secure outer roof rail.
5. Rivet in outer roof rail. > Punch rivets front 
   1. 5.1  Area -A-  > FLOW-FORM RIVET 9A7.008.473.00 

      Area -B-  > FLOW-FORM RIVET 9A7.008.606.00 

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      Punch rivets front

   2. 5.2  Area -A-  > FLOW-FORM RIVET 9A7.008.473.00 

      Area -B-  > FLOW-FORM RIVET 9A7.008.606.00 

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      Punch rivets rear

   3. 5.3  Area -A-  > FLOW-FORM RIVET 9A7.008.473.00 

      Area -B-  > FLOW-FORM RIVET 9A7.008.606.00 

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      Punch rivets on C-pillar and D-pillar

6. Resistance spot-weld outer roof rail > Clinch point on A-post  .

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   Clinch point on A-post

7. Weld aluminium areas -1-  on the body

   > 5X00IN10 WELDING ALUMINIUM

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   Welding area

8. Apply an aluminium weld to the outer roof rail > Marking on C- and D-pillar  .

   > 5X00IN10 WELDING ALUMINIUM

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   Marking on C- and D-pillar

9. Apply an aluminium weld to the outer roof rail > Marking on D-pillar, rear  .

   > 5X00IN10 WELDING ALUMINIUM

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   Marking on D-pillar, rear

10. Apply an aluminium weld to the outer roof rail > Marking on B-pillar  .

    > 5X00IN10 WELDING ALUMINIUM

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Marking on B-pillar

11. Apply an aluminium weld to the outer roof rail > Marking on A-post  .

    > 5X00IN10 WELDING ALUMINIUM

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Marking on A-post

12. Fold over roll fold in the door apetures > Sheet metal tabs  using > VAS 6635 - crimping pliers set, 4-piece  .

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    Sheet metal tabs