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Section of rear floor 5D

Section of rear floor 5D

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


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

2. Remove the rear bumper abutment.

3. Drill out the spot-welds and grind down the seam welds for the luggage compartment floor's reinforcement. Note that the seam welds may be MIG brazed.

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 crossmember.

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


7. Measure 50mm from the crossmember where the floor is to be cut.

8. Cut the rear floor and remove it.

9. Align any deformed sheet metal or panels.


To fit



1. Cut the floor so it fits against the flange on the crossmember.

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

3. Position the floor and mark it by scoring a line where the frame members are.

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

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


6. Apply welding primer on all places to be plug or spot welded.

7. Fit the floor and secure it with a few welding clamps.

8. Plug weld on the floor.

9. Seam weld the corner cut-outs.

10. Spot weld the floor to the wheel housing.


11. Fit the rear bumper abutment.

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.


12. Fit the luggage compartment floor reinforcement. Use the rails on the luggage compartment floor as guides for positioning the reinforcement. Plug and seam weld the luggage compartment floor reinforcement.

Certain cars : Replace the MIG brazing.


13. Grind 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 replacement to the underside of the floor.

18. Apply a thin anti-corrosion agent in beams and cavities after painting.