Outer sill
Outer sill |
Depending upon the damage, the two methods described below can be combined.
Replace the middle section of the sill |
1. |
Remove the doors.
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2. |
Cut the rear section of the sill as indicated by the marks. Within the shaded area the cut can be made anywhere depending upon the damage.
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3. |
Cut the lower B-pillar as illustrated. Only cut through the outer panel.
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4. |
Drill out the spot welds.
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5. |
Tap out the sill.
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6. |
Cut the replacement panel so that it fits against the cuts previously made.
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7. |
Drill holes for plug welds on the lower section of the sill against the frame member.
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8. |
Position the replacement panel and make fine adjustments to the sill.
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9. |
Grind all surfaces that are to be welded.
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10. |
Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray
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11. |
Fit the replacement panel in place and secure with clamps. Check and adjust the fit.
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12. |
All-weld the sill joints.
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13. |
Attach the remainder of the sill with spot and plug welds.
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14. |
Grind the welds.
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15. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
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16. |
Apply primer to all bare metal surfaces.
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17. |
Seal joints and seams with sealant.
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18. |
Apply anti-corrosion agent after painting. Use Terotex HV 400 or Mercasol 1.
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Change the front section of the sill |
1. |
Remove the front door
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2. |
Cut the rear section of the sill as indicated by the marks. Within the shaded area the cut can be made anywhere depending upon the damage.
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3. |
Cut the front section of the sill as illustrated. Cut through both panels.
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4. |
Drill out the spot welds.
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5. |
Tap out the sill.
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7. |
Cut away a section of the outer panel of the replacement panel in order to be able to weld the reinforcement. Save the piece which is removed.
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8. |
Drill holes for plug welds in the front sill and in the loose piece.
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9. |
Fit the replacement panel and adjust the rear sill and front reinforcement.
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10. |
Grind the surfaces which are to be welded.
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11. |
Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray
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12. |
Fit the replacement panel in place and secure with clamps. Check and adjust the fit.
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13. |
All-weld the forward sill reinforcement.
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14. |
Allweld the rear section of the sill and the cut out section.
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15. |
Attach the remainder of the sill with spot and plug welds.
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16. |
Grind the welds.
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17. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
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18. |
Apply primer to all bare metal surfaces.
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19. |
Seal joints and seams with sealant.
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20. |
Apply rust protector after painting. Use Terotex HV 400.
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