SAAB WIS ONLINE

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.

2. Cut away the damaged section of the sill. See Joints. The front edge of the sill may be cut max 50 mm above the front wing mounting hole (A). Be careful that the underlying reinforcement is not damaged. The B pillar must be cut below the weld studs.


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.