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Side assembly with reinforcements

Side assembly with reinforcements

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.


To remove


1. Remove the windscreen and rear window .

2. Remove the doors.

3. Remove the roof.

4. Drill out the spot welds. At some of the spot welds it is necessary to drill through a two plates as illustrated (shaded grey).


5. Drill out the spot welds.


6. Drill out the spot welds. Drill out the inner welds only so that the nut piece follows.


7. Drill out the spot welds.


8. Grind away the seam welds on the wheel housing member, the windscreen frame member and the rear roof member.

Some cars : Note that the welds are MIG brazed.


9. Tap out the side.


To fit


1. Straighten all mounting surfaces for the side.

2. Drill holes for plug welds on the forward section of the replacement side.


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

4. Fit the side in place and secure with clamps. Check and adjust the fit.

5. Attach the replacement panel with spot welds.


6. Attach the replacement panel with spot welds.


7. Attach the replacement panel with spot welds.


8. Attach the replacement panel with spot welds.


9. Finally, spot weld the spare part to the B-pillar.


10. Seam weld the replacement panel to the wheel housing member, windscreen frame member and the rear roof member.

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 must be MIG brazed.


11. Grind the welds.

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

13. Fit the roof .

14. Apply primer to all bare metal surfaces.

15. Apply sealant to the joints and seams. Apply rust protector after painting. Use Terotex HV 400.

16. Fit and align the doors.

17. Fit the windscreen and rear window after painting.