Section of rear floor 5D

Section of rear floor 5D

1.	Position the car in an aligning bench and cross-measure if necessary.

2.	Remove the rear plate.

3.	Drill out the spot welds and grind down the seam welds for the luggage compartment reinforcements. Lift away the reinforcements.

4.	Drill out the spot-welds that secure the floor to the frame members.

5.	Drill out the rear spot-welds in the cross-member.

6.	Drill out the spot-welds holding the sides of the floor.

7.	Measure 50 mm from the cross-member where the floor is to be cut.

8.	Cut away the rear floor and remove it.

9.	Align any deformed sheet metal or panels.

Fitting

1.	Cut the floor so that it fits against the flange on the cross-member.

2.	Grind all the surfaces that are to be welded.

3.	Position the floor and mark it by scribing where the frame members are located.

4.	Remove the floor and drill holes for plug-welding.

5.	Cut out the corners above the frame members so that they fit against the existing floor.

6.	Apply welding primer to all surfaces to be plug or spot-welded.

7.	Fit the floor and fixate with a few welding clamps.

8.	Plug-weld the floor.

9.	Seam-weld the corners that have been cut out.

10.	Spot-weld the floor to the wheel housing.

11.	Fit the rear plate.

12.	Fit the luggage compartment floor reinforcement elements. Use the luggage compartment floor rails as guides so that the reinforcement elements will be correctly positioned. Plug weld and seam weld the luggage compartment floor reinforcement elements.

13.	Smooth off the welds.

14.	Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.

15.	Apply primer to all bare metal surfaces.

16.	Seal joints and seams with sealant.

17.	Apply PVC substitute on the underside of the floor.

18.	Apply a thin coating of anti-corrosion agent in members and cavities after painting.