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Side panel 5D, complete

Side panel 5D, complete

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.


Removing


1. Protect the roof from weld splash and grinding dust.

2. Drill out the spot welds for the roof between the C-pillar and the D-pillar. Drill through the roof panel and side panel only.

Important

Be sure to drill precisely in the centre of each spot weld.



3. Make a 15 mm cut in the roof panel and side plate, 90 mm behind the carrier rack hole. Measure from the centre of the hole. Do not damage the underlying panel. Then, cut forwards along the edge of the roof panel and down to the door opening.


4. Cut a 25 mm long section 17 mm from the edge of the roof panel. Continue cutting in the water channel. Make sure that the underlying panel is not damaged.


5. Drill out the spot welds securing the outer side panel by the door opening and door sill.


6. Drill out the spot welds securing:

• outer side panel by wheel housing and rear side window


• rear bumper abutment

Grind away any seam weld. Note that the seam weld may be MIG brazed.


• the D-pillar

Grind away any seam weld. Note that the seam weld may be MIG brazed.


7. Pull the side panel away from underneath the roof panel and straighten any damaged or deformed sheet.


Fitting


1. Cut and align the spare part.

2. Drill holes for plug-welding in the spare part.

3. Grind clean the surfaces on the body and the spare part that are to be welded.

4. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zink spray.

5. Fit the spare part in place by inserting it under the roof and fixing it with a few welding clamps so that it makes a good fit all round.

6. Weld the spare part at the:

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.


• the D-pillar

Replace any seam weld


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.


• rear bumper abutment

Replace any seam weld.


• rear side window and wheel housing


• door opening and door sill


• roof welds


7. All-weld the joints in:


• front section

• rear section


8. Plug weld the holder for the moulding.


9. Smooth off the welds.

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

11. Apply primer to all bare metal surfaces.

12. Seal joints and seams with sealant.

13. Apply anti-corrosion agent to internal surfaces of the side panel after painting. Use Terotex HV 400.