Section of side panel, rear sill
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Section of side panel, rear sill
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1.
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Position the car in an aligning bench and cross-measure if necessary.
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2.
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Cut the sheet metal as shown in the figure.
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3.
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Drill out the spot-welds.
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5.
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Check the underlying reinforcement. Replace if damaged.
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6.
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Drill out the spot-welds in the reinforcement.
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7.
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Knock away the reinforcement.
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1.
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Drill holes in the reinforcement for plug-welding.
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2.
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Grind clean the surfaces on the body and reinforcement that are to be welded.
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3.
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Apply welding primer to the surfaces that are to be plug welded. Use Terosan Zinkspray.
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4.
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Fit the reinforcement and fixate with a couple of welding clamps.
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5.
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Plug-weld the reinforcement.
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6.
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Roughly cut the new side panel so that it will overlap the joint by three centimetres.
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7.
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Position the side panel on the body and cut it together with the existing panel so that the joint can be welded edge-to-edge.
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8.
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Drill holes on the bottom edge for plug-welding.
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9.
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Grind clean the surfaces that are to be welded.
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10.
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Apply welding primer to the surfaces that are to be plug and spot-welded. Use Terosan Zincspray.
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11.
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Position the side panel and fix it with a few welding clamps.
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12.
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Plug and spot-weld it.
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14.
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Smooth off the welds.
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15.
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Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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16.
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Apply primer to all bare metal surfaces.
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17.
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Seal joints and seams with sealant.
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18.
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Apply anti-corrosion agent to the interior of the side panel. Use Terotex HV 400 or Mercasol 1.
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