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Outer sill, CV

Outer sill, CV


1. Mount the car in an alignment bench with measuring fixture and cross-measure as necessary.

2. Cut the outer sill panel 25 mm below the hinge and 80 mm behind the hole in the sill. Make sure the underlying reinforcement is not damaged.


3. Drill out the spot welds and grind down the welds to the inner sill reinforcement.

4. Knock away the sill panel and align any deformed metal.

5. Roughly cut the spare part so that it will overlap the joints by a couple of centimetres.

6. Fit the new sill in place and fixate it with a few welding clamps.

7. Cut through the new sill and the body together so that the joint can be butt welded.

8. Remove the sill and punch or drill holes for plug welding.

9. Grind the surfaces to be welded on the sill and the body.

10. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zinkspray.

11. Put the sill in place and fixate it with a few weld clamps.

12. Plug weld on the sill.

13. Spot weld the sill in place.


14. All-weld the joints.

15. Grind the welds.

16. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.

17. Apply primer to all ground surfaces. Use Standox 1K Primer.

18. Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.

19. Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.