Installing Outer Side Member (Rear 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 sheetmetal 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.

   > Application depth 0.5 mm 

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   Outer side member (rear 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 (rear section).

   Check gap dimensions.

   >*** 5X00IN Gap dimensions

5. Install outer side member (rear section).
   1. 5.1  Resistance spot-weld the outer side member (rear section) in area -A-  .

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      Rivet area

   2. 5.2  Rivet in the outer side member (rear section) in areas -B-  > FLOW-FORM RIVETS 9A7.008.473.00 

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      Rivet area

   3. 5.3  Rivet in the outer side member (rear section) in area > FLOW-FORM RIVETS 9A7.008.606.00 

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      Rivet area

6. Flare the edge -1-  in the door aperture using > VAS 6635/5 - crimping pliers  .

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   Edge in door aperture

7. Apply a full aluminium weld to the outer side member (rear section) in areas -C and E-  using inert gas.

   >5X00IN10 WELDING ALUMINIUM

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   Outer side member (rear section) and body

8. Apply a full weld (steel) to the outer side member (rear section) in area using inert gas.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Outer side member (rear section) and body