Front door, outer door panel

Front door, outer door panel

1.	The door panel is folded over front and rear edges of the door structure. Grind off the edges so that the door panel comes away from the structure.

2.	Drill out the spot-welds. Make sure to drill only in the door panel so that the underlying door structure is not damaged.

3.	Cut loose the door panel from the door frame as shown in the illustration. Make sure to cut only in the door panel so that the underlying door structure is not damaged.

4.	Detach the door panel from the sealant on the collision reinforcement member.

5.	Knock the door panel loose and lift it away.

6.	Saw a notch in the remaining seam at the front edge.

7.	Drill out the spot-welds holding the remaining metal strips on the inside of the door structure.

8.	Knock away the folded metal on both sides of the inside of the door.

9.	Straighten the edges of the door structure and grind it clean.

To fit

1.	Position the new door panel and mark where to cut.

2.	Cut the door panel to the markings

3.	Grind clean the surfaces on the door panel that are to be welded.

4.	Apply welding primer to the surfaces that are to be spot welded. Use Teroson Zinkspray.

5.	Apply sealant between the collision reinforcement member and the door panel. Use Terostat 1K-PUR.

6.	Apply adhesive to the inside of the front, rear and bottom edges of the door panel. Use Teomix 6700.

7.	Fit the door panel to the door structure and fix it with a couple of welding clamps. Tack-weld the door panel to the door frame.

8.	Fold the front and rear edges of the door panel around the door structure. Start with a plastic mallet and a dolly and then continue with a hammer. Work in stages along each edge.

9.	Fit the door in place and check its alignment with the body. Adjust as necessary.

10.	All-weld the joints between the door panel and door frame.

11.	Smooth off the welds.

12.	Spot-weld on the door panel. Note Do not forget the welds on the inside (door seam).

13.	Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.

14.	Apply primer to all bare metal surfaces. Use Standox 1K Füllprimer.

15.	Use Terostat 1K-PUR to seal joints and metal folds.

16.	Fit a batt of insulating material to the inside of the door panel.

17.	Apply anti-corrosion agent to the door after it has been painted.