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A-pillar, lower part

A-pillar, lower part

Both the A-pillar and sill are provided with reinforcements. These must not be damaged when the A-pillar is cut.

Important

Body reinforcements must only be cut and joined if they are specifically covered in the description of the methods. Unless otherwise stated, it is mandatory to discard and replace the damaged reinforcement component.



1. Position the car in an aligning bench and cross-measure if necessary.

2. Remove the reinforcement on the outside of the wheel housing. It can be used when refitting if it is undamaged.


3. Cut the A-pillar and sill.

If the hinge position is not changed, cut the outer panel around the hinge

Take care not to damage the underlying metal

- On five-door cars, cut the upper part of the A-pillar 70 mm above the marked groove.

- On three-door cars, cut the upper part of the A-pillar in the middle of the marked groove.


4. Drill out the spot-welds.


5. Grind and tap loose the damaged parts of the A-pillar and sill.

6. Align any deformed sheet metal or panels. If only the outer panel is being replaced, proceed to point 33.

7. Cut the sill reinforcement at the front edge. The reinforcement must no be cut in front of the indication on the illustration.


8. Drill out the spot welds in the upper and lower reinforcement and knock them away.

9. Align any deformed sheet metal or panels.


10. Cut the new sill reinforcement so that it overlaps the intended joint by approximately three centimetres.

11. Fit the new sill reinforcement and fixate with a couple of welding clamps.

12. Cut through the new and old sill reinforcement at the same time so that the joint can be welded edge-to-edge.

13. Remove the new sill reinforcement. Grind clean the surfaces to be welded on the reinforcement and the body.

14. Apply welding primer on the surfaces to be spot-welded. Use Teroson Zinkspray.

15. Fit the reinforcement and fixate with a couple of welding clamps.

16. Spot-weld the sill reinforcement.


17. All-weld the joint.

18. Grind clean the surfaces to be welded on the body and on the new lower A-pillar reinforcement.

19. Apply welding primer on the surfaces to be spot-welded. Use Teroson Zinkspray.

20. Fit the A-pillar reinforcement and fixate with a couple of welding clamps.

21. Spot-weld the A-pillar reinforcement.

22. Grind the welds.

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

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

25. Cut the outer panel spare part so that it overlaps the intended joints with approximately three centimetres.

26. Drill holes for the hinge mountings.


27. Tighten the hinges on the outer panel. Scratch around the hinge to mark the position.

28. Remove the hinges and drill holes for plug-welding in the marking for the hinges. The outer panel must be welded to the reinforcement so that the hinges then can be welded to the outer panel and the reinforcement.

29. Drill holes for plug-welding in the outer panel.


30. Grind clean the surfaces to be welded on the outer panel and on the body.

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

32. Fit the outer panel and fixate with a couple of welding clamps.

Cut out for the hinges only if the outer panel is being replaced.

Proceed to point 42 if only the outer panel is being replaced.

33. Tighten the hinges to the A-pillar.

34. Fit door, front wing and bonnet, adjust the door opening. Mark the joints.

35. Remove the door, front wing, bonnet and hinges. Cut through the outer panel and body at the same time by the intended joints so that the joints can be welded edge-to edge.


36. Plug-weld the outer panel to the reinforcement by the markings for the hinges.


37. Grind the welds.

38. Put the hinges in place and screw them on.

39. Fit door, front wing and bonnet, adjust the exact position of the hinges.

40. Fasten the hinges with a few tack welds and remove the door.

41. Spot and plug weld on the outer panel.


42. All-weld the joints on the A-pillar and sill.

43. Weld the hinges into place.


44. Weld on the reinforcement on the outside of the wheel housing.

45. Grind the welds.

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

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

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

49. Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400 or Mercasol 1.