Prepare Longitudinal Member Outer Shell On Rocker Panel For Installation - Ar63.30-P-1102-02SRA

Model 453.3/4 

1. Expose spot welds on A-pillar outer section (1) and cut out (area M).

   Cut out spot welds on insides.

   Fig 1: Locating Area M

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2. Grind mating surfaces down to bare metal on A-pillar outer section (1) in the crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

3. Grind mating surfaces on A-pillar outer section reinforcement (4) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

4. Remove grinding dust and drill chips.
5. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint (area N).

   Fig 2: Locating Area N

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   Otherwise adhesion problems may occur.

6. Grind mating surfaces on longitudinal member outer shell on entry (3) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

7. Remove grinding dust.
8. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint (area O).

   Otherwise adhesion problems may occur.

   Fig 3: Locating Area O

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9. Assemble A-pillar outer section, longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4), then fit and fix in place.
10. Mark position longitudinal member shell on entry (3) and A-pillar outer section reinforcement (4).
11. Disassemble A-pillar outer section, longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4).
    Fig 4: locating Components (3) & (4)

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12. Apply 2-component adhesive to A-pillar outer section reinforcement (4) in crosshatched area (area N).

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

    Fig 5: Locating Area N

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13. Apply 2-component adhesive to longitudinal member outer shell on entry (3) in crosshatched area (area O).

    Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.

    Fig 6: Locating Area O

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14. Longitudinal member shell on entry (3) and A-pillar outer section reinforcement (4) (areas P ₁ , P ₂ and P₃ ).
    Fig 7: Locating Areas P 1, P 2 and P3

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15. Assembly A-pillar outer section (1) and longitudinal member outer shell on entry (3), then fit and fix in place.
16. Mark position on A-pillar outer section (1) and longitudinal member shell on entry (3).
17. Drill 6.7 mm rivet holes A-pillar outer section (1) and longitudinal member outer shell on entry (3) (areas Q ₁ and Q ₂ ).
18. Deburr rivet A-pillar outer section (1) and longitudinal member outer shell on entry (3) on both sides.
    Fig 8: Locating Sections (1) & (3)

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19. Rivet A-pillar outer section (1) and longitudinal member outer shell on entry (3) with 6.5x12.5 rivets (areas R and S).
    Fig 9: Locating Areas R, S, T, U 1 & U2

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20. A-pillar outer section (1), longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4) (areas T, U ₁ and U₂ ).