Part of rear side plate, 5D, spare part complete side
Part of rear side plate, 5D, spare part complete side |
Certain welded joints on the car may be MIG brazed with bronze as the filling material. A MIG brazed seam may be recognised from the gold colour of the joint. A MIG brazing must always be replaced by a new MIG brazing.
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Replacement |
1. |
Cut according to the markings.
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2. |
Cut as follows: 20 mm below the plate joint and 140 mm above the plate joint. The cutting is necessary in order to access the spot welds underneath.
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3. |
Drill out the spot welds and lift away the loose piece.
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4. |
Cut the reinforcement. The cut must be made in the centre of the oval hole.
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5. |
Drill out the spot welds on the inner reinforcement.
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6. |
Drill out the spot welds on the inside to the reinforcement.
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7. |
Drill out the spot welds at the rear light cluster plate.
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8. |
Drill out the spot welds by the door opening and the window opening.
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9. |
Grind away the MIG brazing.
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10. |
Drill out the spot welds in the luggage compartment.
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11. |
Tap loose the side panel and break it loose from the wheel housing's adhesive.
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12. |
Straighten any deformed panels. Adjust and align all fitting surfaces.
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13. |
Cut the replacement panel so that it fits with the cuts previously made.
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14. |
Cut away a piece in order to access the reinforcement. Cut the reinforcement so that it corresponds with the cutting on the car.
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15. |
Drill out certain spot welds from the reinforcement so that it detaches from the section of the spare part that is not used.
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16. |
Drill holes for plug welding where appropriate.
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17. |
Grind clean the surfaces on the body and replacement panel that are to be welded.
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18. |
Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray
Apply Teroson 6700 on the edge of the outer wheel housing. |
19. |
Fit the spare part in place and make fine adjustments.
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20. |
Fully weld the inner reinforcement.
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21. |
Spot weld by the door opening and the window opening.
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22. |
Spot weld on the inside to the reinforcement.
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23. |
Plug weld at the rear light cluster plate.
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24. |
Plug weld in the luggage compartment
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26. |
Fully weld all joints.
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27. |
Replace the MIG braze.
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28. |
Smooth off the welds.
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29. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
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30. |
Apply primer to all bare metal surfaces.
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31. |
Seal joints and seams with sealant.
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32. |
Apply rust protector after painting. Use Terotex HV 400.
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