Inner, lower A-pillar with sill, 4D
Inner, lower A-pillar with sill, 4D |
Replacement |
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.
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1. |
Remove
Outer A-pillar with reinforcement, 4D
.
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2. |
Drill out the spot welds on the front transverse reinforcement.
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3. |
Drill out the spot welds from the inside as illustrated. Drill straight through the panels. The drill holes are useful for fitting.
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4. |
Tap loose the front transverse reinforcement.
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5. |
Cut the centre sill as illustrated.
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6. |
Drill out the spot welds.
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7. |
Tap loose the centre sill.
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8. |
Cut the inner sill as illustrated.
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9. |
Cut the inner, lower A-pillar as illustrated.
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10. |
Drill out the spot welds and grind down the MIG brazing.
If necessary, drill out the spot welds on the dashboard reinforcement. |
11. |
Tap loose the inner, lower A-pillar.
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12. |
Align any deformed plates.
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13. |
Cut the front edge of the spare part inner, lower A-pillar to roughly the right size. Cut so that it overlaps the previous cut.
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14. |
Position the inner, lower A-pillar roughly and secure with welding clamps.
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15. |
Cut the inner sill (spare part) so that it measures 460 mm.
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16. |
Position the inner sill and secure with welding clamps.
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17. |
Position the inner, lower A-pillar. It must be 260 mm from the previous cut.
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18. |
Now cut the front edge of the inner, lower A-pillar so it is edge-to-edge with the previous cut.
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19. |
Grind the surfaces which are to be welded.
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20. |
Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray.
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21. |
Secure the spare part with spot and plug welds. Replace the MIG brazing.
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22. |
Seam weld as illustrated. Weld the inside and outside of the inner sill.
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23. |
Apply primer to the internal seam welds. Use Standox 1k.
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24. |
Cut the centre sill so that it matches the previous cut.
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25. |
Grind the surfaces which are to be welded.
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26. |
Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray.
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27. |
Position the centre sill and secure it with welding clamps.
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28. |
Weld the centre sill in place.
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29. |
Smooth off the welds.
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30. |
Fit the front transverse reinforcement and support. Use the dill holes from the spot welds.
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31. |
Grind the welds and apply rustproofing. Use Terotex HV 400.
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32. |
Fit
Outer A-pillar with reinforcement, 4D
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33. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
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34. |
Apply primer to all bare metal surfaces. Use Standox 1K.
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35. |
Use Terostat 1K-PUR to seal joints and metal folds.
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36. |
Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.
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