Inner side panel (conv.)
Inner side panel (conv.) |
The following section describes how to change the inner side panel, inner B pillar, inner side reinforcement and strap guide mounting.
1. |
Mount the car in an alignment bench with measuring fixture and cross-measure as necessary.
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2. |
Remove the side panel.
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3. |
Remove the rear section of the door frame.
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4. |
Remove the outer side reinforcement and the B pillar reinforcement.
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5. |
Remove the rear section of the outer sill reinforcement.
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6. |
Drill out the spot welds and grind away the seam welds that secure the inner side panel.
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7. |
Grind down the seam welds securing the inner side panel.
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8. |
Knock away the inner side panel.
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9. |
Grind down the welds securing the end of the torsion box.
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10. |
Cut away the outer section of the torsion box as illustrated. The outer section is to be refitted on assembly.
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11. |
Grind the welds.
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12. |
Drill out the spot welds and grind away the seam welds that secure the inner side reinforcement. Remove the inner side reinforcement, inner B pillar and belt guide mounting.
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13. |
Grind clean the surfaces to be welded on the spare part and the body.
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14. |
Drill holes for plug welding in the spare part.
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15. |
Apply welding primer to the surfaces to be spot welded on the spare part and the body. Use Teroson Zinkspray.
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16. |
Fit the inner side reinforcement in place on the inner side panel. Fit the inner side panel in place on the body and fix it with a few welding clamps.
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17. |
Put the inner B pillar and the belt guide mounting in place and secure them with some welding clamps. Measure in the exact position with the measuring fixture.
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18. |
Tack on the inner B pillar with a few welds.
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19. |
Fit the outer sill reinforcement. See
Rear section of outer sill reinforcement (conv.)
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20. |
Put the B pillar reinforcement, the outer side reinforcement, the door frame, side panel and door in place. Check the fit.
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21. |
Remove the side panel, door frame, the outer side reinforcement and the B pillar reinforcement. Seam weld the inner B pillar and belt guide mounting in place.
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22. |
Weld the inner B pillar to the side panel and sill reinforcement.
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23. |
Weld the inner side panel in place.
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24. |
Spot weld the inner side panel in place and then seam weld the welds in the wheel housing.
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25. |
Fit the outer side reinforcement and outer B pillar reinforcement. See
Outer side reinforcement with outer B pillar reinforcement (conv.)
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26. |
Put the removed section of torsion box in place and seam weld it on.
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27. |
Fit the door frame and side panel. See
Door frame (conv.) and
Side panel (conv.)
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28. |
Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
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29. |
Apply primer to all bare metal surfaces. Use Standox 1K Füllprimer.
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30. |
Seal joints and metal folds with putty. Use Terostat 1K-PUR.
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31. |
Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.
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