Outer sill
Outer sill |
The sill and the B pillar are both reinforced. This reinforcement must not be damaged when the sill is cut.
Important | ||
Body reinforcement components should be cut and joined only if they are specifically covered in the description of methods. Unless otherwise stated, a damaged reinforcement component must be discarded and a new one fitted in its place. This is mandatory. |
||
1. |
Mount the car on an aligning bench and realign to the correct measurements if necessary.
|
3. |
Drill out the spot welds along the top of the sill.
|
4. |
Drill out the spot welds on the underside of the sill.
|
5. |
Knock the sill loose and remove it.
|
6. |
Realign any deformed metalwork.
|
7. |
Cut the spare part roughly to size so that it will overlap the joints by about three centimetres.
|
8. |
Position the spare part and fix it with a few welding clamps.
|
9. |
Remove the doors. Cut through the spare part and the body simultaneously so that the joints can be welded edge-to-edge.
|
10. |
Remove the spare part and drill or punch holes for plug welding in the underside of the sill.
|
11. |
Use a grinder to clean the areas on the spare part and body that are to be welded.
|
12. |
Apply welding primer to the surfaces which are to be spot welded or plug welded. Use Teroson Zinkspray.
|
13. |
Position the spare part and fix it with a few welding clamps. Fix the sill with a couple of tack welds.
|
14. |
Remove the doors and spot weld the top of the sill in place.
|
15. |
Spot weld the lower edge of the sill.
|
16. |
Plug weld the underside of the sill to the reinforcement components in the sill and B pillar.
|
17. |
Weld the joints at the rear wheel housing, B pillar and front wheel housing.
|
18. |
Grind the welds clean.
|
19. |
Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
|
20. |
Apply primer to all surfaces that have been ground clean. Use Teroson Zinkspray.
|
21. |
Seal joints and metal folds with putty. Use Terostat 1K-PUR.
|
22. |
Apply anti-corrosion agent to inside surfaces after painting. Use Terotex HV 400 or Mercasol 1.
|