Door frame (conv.)
Door frame (conv.) |
Replacing a door frame where both hinges are undamaged is described below.
1. |
Mount the car in an alignment bench with measuring fixture and cross-measure as necessary.
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2. |
Remove any side panels.
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3. |
Cut the door frame below the reinforcement under the upper hinge.
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4. |
Cut around the hinge.
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5. |
Drill out the spot welds and cut the sill. Be careful not to damage the underlying reinforcement. Grind down the welds to the sill reinforcement.
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6. |
Knock loose the door frame and align any damaged metalwork.
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7. |
Roughly cut the new door frame and cut a hole for the lower hinge.
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8. |
Drill holes for plug welding the door frame.
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9. |
Put the door frame in place and secure it with some welding clamps.
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10. |
Fit in place the side panel (if its removed), the door, bonnet and front wing and adjust the door frame to its correct position.
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11. |
Mark the cutting position.
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12. |
Remove the side panel, door, front wing, bonnet and door frame and cut as indicated by the marking.
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13. |
Grind the surfaces to be welded on the new door frame.
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14. |
Use a grinder to clean the areas on the body that are to be welded.
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15. |
Apply welding primer to the surfaces which are to be spot welded. Use Teroson Zinkspray.
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16. |
Put the door frame in place and secure it with some welding clamps.
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17. |
Plug weld the door frame.
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18. |
All-weld the joint below the upper hinge and around the lower hinge. Spot weld and seam weld the sill reinforcement.
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19. |
Grind the welds clean.
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20. |
Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
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21. |
Apply primer to all surfaces that have been ground clean. Use Standox 1K Füllprimer.
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22. |
Seal joints and metal folds with putty. Use Terostat 1K-PUR.
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23. |
Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.
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