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Door frame, three-door body

Door frame, three-door body


1. The side panel should already have been removed.

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

3. 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.


4. Grind away the seam welds securing the door frame to the front wheel housing. If the hinges are undamaged cut the panel around the hinges.


5. Drill out the spot welds.


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

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


8. 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.

9. 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

10. 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. Use Teroson Zinkspray.

12. Cut holes for the hinges if they have not been removed. Position the spare part and fix it with a few welding clamps.

13. If the hinges have been removed:

Attach the hinges on the door frame with nuts and bolts. Score around the hinge to mark out its position.

14. Remove the hinges and drill holes for plug welding in the hinge markings. The outer panel is to be welded to the reinforcement so that the hinges can subsequently be welded to both the outer panel and the reinforcement.

15. Fit the front wing, door and side panel in place and check the fit.

16. If the hinges have been removed:

Fix the hinges with a few tack welds.

17. Remove the front wing, door and side panel. Weld the door frame in place.


18. Plug weld the underside of the door frame to the reinforcement in the B pillar and weld the outer panel around the hinges if they are in place.

19. If the hinges have been removed:


Weld the hinges in place.

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

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


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


23. Grind the welds clean.

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

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

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

27. Apply anti-corrosion agent to the inside surfaces of the door frame after painting. Use Terotex HV 400 or Mercasol 1.