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Front inner sill

Front inner sill

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, it may be used for fitting. Grind away the welds and drill out the spot welds. Note that the seam welds may be MIG brazed. Knock loose the reinforcement.


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


4. Cut the sill max. 50mm behind the measuring point or max. 150mm in front of the measuring point.

5. Drill out the spot welds.


6. Grind off the seam weld at the windscreen member. Note that the seam welds may be MIG brazed.

7. Knock loose the outer panel.

Important

The sill reinforcement must absolutely never be joined at any point other than at the rear edge of the square hole closest to the B-pillar.


8. Cut the sill reinforcement at the rear edge of the square hole in front of the B-pillar.


9. Drill out the reinforcement's spot welds.

10. Grind off the seam weld and grind off the welds on the inside. Note that the seam welds may be MIG brazed.


11. Knock loose the reinforcements.

12. Cut the inner sill as illustrated.


13. Drill out the spot welds on the sill.


14. Drill out the spot welds for the A-pillar's inner cover panel, (IMAGE)

15. Grind off the seam weld at the windscreen member and A-pillar. Note that the seam welds may be MIG brazed.


16. Knock loose the inner sill and the A-pillar's inner cover panel.

17. Align any deformed plates.

18. If necessary, replace the inner cross-reinforcement .


To fit


1. Cut the spare sill so that it fits the previous cut.

2. Grind the surfaces to be welded. Apply welding primer to the surfaces to be spot and plug welded.

3. Adjust the inner A-pillar's cover panel and secure using welding clamps.

4. Adjust the inner sill and secure using welding clamps.

5. Spot and plug weld the spare parts.


6. Seam weld the joint.

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.


7. Replace the seam welds. Note that some seam welds may be MIG brazed.


8. Grind the welds.

9. Apply primer to the internal seam weld.

10. Cut the centre sill reinforcement at the square hole. Make sure that it fits the previous cut.

11. Grind the surfaces to be welded on the sill reinforcement and A-pillar reinforcement.

12. Apply welding primer to the locations to be spot and plug welded.

13. Adjust the centre sill and A-pillar reinforcement using welding clamps.

14. Spot, plug and seam weld the centre sill into position.


15. Weld the A-pillar reinforcement into position on the outside and inside.


16. Grind the welds.

17. Apply primer to the internal weld.

18. Cut the outer panel so that it matches previous cuts.

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

20. Apply welding primer to the surfaces that are to be welded. Use Terosan Zinkspray.

21. Align the outer panel and secure it with welding clamps.

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.


22. Spot, plug and seam weld the spare part into position.

Certain cars : Replace the MIG brazing.


23. 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.


24. Fit the outer A-pillar reinforcement on the outside of the wheel housing.

Certain cars : Replace the MIG brazing.


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

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

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

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