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Rear section, outer sill reinforcement, CV

Rear section, outer sill reinforcement, CV


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

2. Remove the side panel.

3. Remove the rear section of the door frame.

4. Remove the outer B pillar reinforcement.

5. Cut the sill reinforcement as illustrated.


6. Drill out the spot welds and grind away the seam welds.

7. Knock away the sill reinforcement and align any deformed metal.

8. Cut the new sill reinforcement so that it will overlap the joint.

9. Put the new sill reinforcement in place and secure it with some welding clamps.

10. Cut through the new sill reinforcement and the existing one at the same time so that the joint can be butt welded.

11. Remove the new sill reinforcement and drill holes for plug welding.

12. Grind clean the surfaces to be welded.

13. Grind clean the surfaces that are to be welded on the body.

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

15. Put the sill reinforcement in place and secure it with some welding clamps.

16. Spot weld the sill reinforcement in a few places so it is secure. Spot weld the rest together with the outer sill panel.


17. Plug weld the sill reinforcement in place.

18. All-weld the joint on the sill reinforcement.

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

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

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

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

23. Fit the B-pillar reinforcement, door frame and side panel.