Preparing Outer Side Member (Front Section) For Installation

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 in and secure the outer side member (front section) -A and D-  .

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   Possible separation points on outer side member (front section)

   1. 1.1  Cut outer side member (front section) -A and D-  at the points where it joins the body leaving an overlap of 30 mm.
   2. 1.2  Fit in outer side member (front section) -A and D-  .
   3. 1.3  Make cuts through the outer side member (front section) and body in the overlap areas -A and D-  .

      Check gap dimensions.

      >*** 5X00IN Gap dimensions

2. Punch holes for flow-form rivets in areas -B-  using > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - compact booster  .

   >5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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   Rivet area

3. Remove outer side member (front section).
4. Cut sheetmetal inserts used as a welding backing strip for the two weld areas from the old outer side member (front section).

   >5X00IN10 WELDING ALUMINIUM

5. Prepare connection areas > Outer side member (front section)  for joining.

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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

6. Prepare connection areas > Outer side member (front section)  for applying a full aluminium weld using inert gas.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Outer side member (front section)

   Yellow	Applying full weld using inert gas (steel)
   Magenta	Applying full aluminium weld using inert gas >5X00IN10 WELDING ALUMINIUM