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A-pillar, lower part

A-pillar, lower part

Certain weld joints on the car may be MIG brazed whereby the filler material is bronze rod. The characteristic sign of MIG brazing is that the joint is gold coloured. MIG brazing must always be replaced with new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


To remove

The A-pillar is reinforced. The reinforcement must not be damaged when cutting the A-pillar.

Important

Body reinforcements must only be cut and joined if they are specifically covered in the description of the methods. Unless otherwise stated, it is mandatory to discard and replace the damaged reinforcement component.



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

2. Remove the reinforcement on the outside of the wheel housing. If it is undamaged then it can be used during fitting. Note that the seam welds may be MIG brazed.


3. Cut the A-pillar outer panel roughly at the centre of the measuring point. Take care not to damage the panel underneath.


4. Cut the A-pillar outer panel at the centre of the measuring point. Take care not to damage the panel underneath.

5. Drill out the spot-welds.

6. Lift away the outer sheet.

7. If the reinforcement is damaged, drill out the spot welds.


8. Lift away the reinforcement.

9. Align any deformed sheet metal or panels.


To fit



1. Drill holes in the A-pillar reinforcement for plug welding.

2. Grind clean the surfaces to be welded on the body and the new A-pillar reinforcement.

3. Apply welding primer to the surfaces that are to be plug-welded. Use Terosan Zink spray.

4. Align the A-pillar reinforcement in position and secure it with a few welding clamps.

5. Plug weld the A-pillar reinforcement.

6. Grind the welds.

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

8. Apply primer to all bare metal surfaces. Use Standox 1K Fullprimer.

9. Cut the outer panel spare part roughly.

10. Drill holes for plug welding the outer panel and grind the surfaces to be welded on the outer panel and the body.

11. Apply welding primer to the surfaces to be spot and plug welded. Use Terosan Zink spray.

12. Measure out the outer panel and cut it so that it fits the joints.

13. Fit the outer panel and fixate with a couple of welding clamps.

14. Plug and spot weld the outer panel.


15. All-weld the joints.

16. Grind the welds.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


17. Weld on the reinforcement on the outside of the wheel housing.

Certain cars : Replace the MIG brazing


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

19. Apply primer to all ground surfaces. Use Standox 1K Primer.

20. Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.

21. Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.