Installing Outer Side Member (Front Section)

Information 

• Apply adhesive evenly over the entire bonding surface. 

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• Bonding 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 sheet metal insert > Sheetmetal insert  used as a welding backing strip on the body.

   >5X00IN10 WELDING ALUMINIUM

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   Sheetmetal insert

2. Apply adhesive on joint areas > Bonding area  of the body. > Application depth 0.5 mm 

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   Bonding area

   Yellow	Bonding and resistance spot-welding > 5X00IN21 Working with body structural adhesive
   Orange	Bonding and riveting > 5X00IN21 Working with body structural adhesive

3. Apply adhesive in the marked area > Outer side member (front section)  . > Application depth 0.5 mm 

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   Outer side member (front section)

   Yellow	Bonding and resistance spot-welding > 5X00IN21 Working with body structural adhesive
   Orange	Bonding and riveting > 5X00IN21 Working with body structural adhesive

   1. 3.1  Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm 
4. Fit in and secure outer side member (front section).

   Check gap dimensions.

   >*** 5X00IN Gap dimensions

5. Apply a full aluminium weld to the outer side member (front section) in the areas -A and D-  using inert gas.

   >5X00IN10 WELDING ALUMINIUM

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   Outer side member (front section) and body

6. Apply a full weld (steel) to the outer side member (front section) in area -F-  using inert gas.

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   Outer side member (front section) and body

7. Install outer side member (front section).
   1. 7.1  Resistance spot-weld the outer side member (front section) in area -A-  .

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      Rivet areas

   2. 7.2  Rivet in the outer side member (front section) in area > FLOW-FORM RIVETS 9A7.008.606.00 

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      Rivet areas

8. Flange the edge -1-  in the front door aperture using > VAS 6635/5 crimping pliers  .

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   Edge in door aperture