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Part of side panel, five-door body

Part of side panel, five-door body

If the roof is undamaged, the side panel can be cut and joined further down the D pillar. Damage to the paintwork on the roof will then be avoided when the new side panel is welded in place.

Important

The D pillar may be cut only as described below. If it is not, the reinforcement inside it could very likely be damaged.



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

2. Cut the D-pillar 40 mm above the ball pin where the tailgate gas spring is attached.


3. Cut the C pillar as shown.

4. Drill out the spot welds.


Drill out the spot welds.


Drill out the spot welds.


5. Knock loose the side panel and realign any deformed metalwork.

6. Cut the spare part roughly to size to that it will overlap the joints by about three centimetres.

7. Drill holes for plug welding in the spare part.

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

9. Cut through the spare part and the body simultaneously so that the joint can be welded edge-to-edge.

10. Remove the spare part and use a grinder to clean the areas on the spare part and body that are to be welded.

11. Apply welding primer to the surfaces which are to be spot welded or plug welded. Use Teroson Zinkspray.

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

13. Spot weld the spare part in place.


14. Plug weld the spare part.


15. Weld the joints.

16. Grind the welds clean.

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

18. Apply primer to all surfaces that have been ground clean. Use Standox 1K Füllprimer.

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

20. Apply anti-corrosion agent to the inside surfaces of the side panel after painting. Use Terotex HV 400 or Mercasol 1.