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Part of door frame, three-door body

Part of door frame, three-door body


1. Mount the car on an aligning bench and realign to the correct measurements if necessary.


2. Grind away the welds and drill out the spot welds securing the reinforcement to the outside of the wheel housing. If the reinforcement is undamaged it can be refitted.

3. Grind away the seam welds securing the door frame to the front wheel housing.


4. Cut away the damaged part of the door frame, see Joints. Avoid cutting into the underlying metalwork. In the case of undamaged hinges, the panel is cut around the hinges.

5. Drill out the spot welds.

6. Knock loose the door frame and align any damaged metalwork.

7. Cut the spare part roughly to size so that it will overlap the joint by about three centimetres.

8. Cut holes for the hinges if they have not been removed.

9. Position the spare part and fix it with a few welding clamps.

10. Cut through the spare part and the existing door frame simultaneously so that the joints can be welded edge-to-edge.


11. If the hinges are removed:

Remove the spare part and drill holes for the hinge mountings at the pre-stamped punch marks in the A pillar.

12. Drill holes in the hinges as shown in the illustration. Use a 6.0 mm bit.


Upper hinges: A = 20.0 mm, B = 26.6 mm

Lower hinges: A = 25.1 mm, B = 26.6 mm

13. Drill hole for plug welding in the front edge of the door frame.


14. Use a grinder to clean the areas on the spare part and body that are to be welded.

15. Apply welding primer to the surfaces which are to be spot welded. Use Teroson Zinkspray.

16. Position the spare part and fix it with a few welding clamps.

17. If the hinges have been removed:

Screw the hinges to the door frame with nuts and bolts.

18. Fit the front wing and door in place and check their fit.

19. If the hinges have been removed:

Fix the hinges with a few tack welds.

20. Remove the door and front wing. Spot weld the door frame in place.


21. Plug weld the front of the door frame in place.

22. Seam weld the door frame to the wheel housing.

23. All-weld the joints and if the hinges are in place weld the outer panel around the hinges

24. If the hinges have been removed:


Weld the hinges in place.

25. Remove the nuts and bolts and weld up the holes in the hinges.

26. Weld the reinforcement to the outside of the wheel housing.


27. Grind the welds clean.

28. Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.

29. Apply primer to all surfaces which have been ground clean. Use Standox 1K Füllprimer.

30. Seal joints and metal folds with putty. Use Terostat 1K-PUR.

31. Apply anti-corrosion agent to inside surfaces after painting. Use Terotex HV 400 or Mercasol 1.