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A-pillar outer panel, CV

A-pillar outer panel, CV

Certain welded joints on the car may be MIG brazed with bronze as the filling material. A MIG brazed seam may be recognized from the gold colour of the joint. A MIG brazing must always be replaced by a new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.



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

2. Remove the Front wing , Bonnet and Door .

3. Drill out the spot welds as illustrated. Drill out the upper welds only so that the nut piece follows.


4. Grind away the welds, according to the illustration. Note that the seam welds are MIG brazed.

5. Knock loose the reinforcement.

6. Cut the windscreen frame outer panel 250 mm from the outer edge of the A-pillar. Do not cut the underlying panel.


7. Grind the seam welds as illustrated.

8. Drill out the spot welds holding the A-pillar outer panel.

9. Tap away the A-pillar outer panel and align any deformed sheet metal or panels.

10. Drill holes for plug welding in the new A-pillar outer panel.

Important

The outer panel of the windscreen frame is only to be plug welded as the total material thickness is too great for spot welding.

Make sure the holes for plug welding are not positioned over the underlying spot welds. Otherwise, there is a risk of the existing spot welds coming loose.


11. Apply welding primer to the surfaces to be plug welded. Use Teroson Zink Spray

12. Place the A-pillar outer panel in fitting position and secure it with welding clamps.

13. Align the A-pillar outer panel exactly.

14. Plug weld the A-pillar outer panel.

Important

Do not place all the spot welds in a row; distribute them and allow the material to cool. Very high risk for heat displacement.



15. All-weld the joint at the upper end of the upper A-pillar outer panel.

16. Seam weld the A-pillar outer panel as illustrated.

17. Place the reinforcement into position against the outside of the front wheel housing. Spot and plug weld


Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


18. Seam weld and continuous weld on the outside of the front wheel housing. Note that the welds must be MIG brazed.

19. Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.

20. Apply primer to all bare metal surfaces. Use Standox 1K.

21. Use Terostat 1K-PUR to seal joints and metal folds.

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

23. Fit the Front wing , Bonnet and Door .