Door frame (conv.)

Door frame (conv.)

Replacing a door frame where both hinges are undamaged is described below.

Mount the car in an alignment bench with measuring fixture and cross-measure as necessary.

Remove any side panels.

Cut the door frame below the reinforcement under the upper hinge.

Cut around the hinge.

Drill out the spot welds and cut the sill. Be careful not to damage the underlying reinforcement. Grind down the welds to the sill reinforcement.

Knock loose the door frame and align any damaged metalwork.

Roughly cut the new door frame and cut a hole for the lower hinge.

Drill holes for plug welding the door frame.

Put the door frame in place and secure it with some welding clamps.

10.

Fit in place the side panel (if its removed), the door, bonnet and front wing and adjust the door frame to its correct position.

11.

Mark the cutting position.

12.

Remove the side panel, door, front wing, bonnet and door frame and cut as indicated by the marking.

13.

Grind the surfaces to be welded on the new door frame.

14.

Use a grinder to clean the areas on the body that are to be welded.

15.

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

16.

Put the door frame in place and secure it with some welding clamps.

17.

Plug weld the door frame.

18.

All-weld the joint below the upper hinge and around the lower hinge. Spot weld and seam weld the sill reinforcement.

19.

Grind the welds clean.

20.

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

21.

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

22.

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

23.

Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.