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Outer A-pillar with reinforcement, 4D/5D

Outer A-pillar with reinforcement, 4D/5D

Some weld joints on the car may be MIG brazed, with brazing material of bronze wire. An MIG braze can be identified by its yellow colour. Always replace an MIG braze with another MIG braze.

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.


Replacement


1. Drill out the spot welds. Drill out the inner welds only so that the hinge's nut piece follows.


2. Grind away the seam welds and all-welds. Note that the welds could be MIG brazed.

3. Knock loose the reinforcement.

Important

Do not cut the metal underneath.


4. Cut the A-pillar as illustrated. Cut 15 mm below the measurement point.


5. Cut the sill as illustrated. Cutting is permitted anywhere within the shaded area, with the point depending on the damage.

Important

Do not cut the metal underneath.



6. Drill out the spot welds. In some places it is necessary to drill through two plates.


7. Tap loose the part with the reinforcement.

8. Cut the spare part to match the previous cuts (use a front side with reinforcements).

9. Grind clean the surfaces to be welded.

10. Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray

11. Fit the replacement panel in place and secure with clamps. Check and adjust the fit.

12. All-weld the joints.


13. Spot and plug weld the replacement piece in place.


14. Place the reinforcement in position. Spot and plug weld.


15. Seam weld and all-weld the reinforcement as illustrated.

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.


Some cars : Note that the seam welds and all-welds must be MIG brazed.

16. Smooth off the welds.

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

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

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

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