Part of door frame, five-door body
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Part of door frame, five-door body
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In the description below, the top edge of the door frame is cut and joined in front of the C pillar and the bottom edge next to the rear wheel housing. When replacing a complete door frame the side panel will have to be removed.
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1.
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Mount the car on an aligning bench and realign to the correct measurements if necessary.
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2.
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Drill out the spot-welds and remove the reinforcement on the outside of the wheel housing. The reinforcement can be refitted if it is undamaged.
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3.
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Grind away the seam welds securing the door frame to the front wheel housing.
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4.
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Cut the door frame as shown in the illustration, see
Joints. The reinforcement on the upper edge of the C pillar must not be damaged.
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5.
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If the hinges are undamaged the panel is cut around the hinges.
If the hinges are damaged they must be removed.
Drill out the spot welds and knock loose the door frame. All spot welds on the lower flange should be drilled out on the lower edge.
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6.
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Realign any deformed metalwork.
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7.
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Cut the spare part roughly to size so that it will overlap the joints by about three centimetres. Cut out for the hinges if they are still in place.
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8.
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Position the spare part and fix it with a few welding clamps.
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9.
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Cut through the spare part and the body simultaneously so that the joints can be welded edge-to-edge.
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10.
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If the hinges have been removed:
Drill holes in the hinges as shown in the illustration. Use a 6 mm drill bit.
Front door, upper hinge:
A = 20.0 mm, B = 26.6 mm
Front door, lower hinge:
A = 25.1 mm, B = 26.6 mm
Rear door, upper hinge:
A = 24.1, B = 30.2 mm
Rear door, lower hinge:
B = 25.1 mm A = 30.2 mm
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11.
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Drill holes for the hinge mountings in the spare part according to the pre-stamped marks in the B pillar.
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12.
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Screw the hinges to the spare part with nuts and bolts.
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13.
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Drill holes for plug welding in the underside of the spare part.
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14.
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Use a grinder to clean the areas on the spare part and body that are to be welded.
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15.
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Apply welding primer to the surfaces which are to be spot welded or plug welded. Use Teroson Zinkspray.
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16.
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Position the spare part and fix it with a few welding clamps.
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17.
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Fit doors, front wing and bonnet in place and adjust the door apertures.
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18.
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Fix the hinges with a couple of tack welds.
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19.
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Remove the doors, front wing and bonnet.
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20.
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Spot weld the door frame in place.
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21.
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Plug weld the underside of the door frame in place.
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22.
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Weld the joints on the door frame.
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23.
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Weld the hinges in place.
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24.
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Remove the nuts and bolts and weld up the holes in the hinges.
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25.
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Plug weld the door frame to the front wheel housing.
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26.
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Weld the reinforcement to the outside of the wheel housing.
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27.
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Grind the welds clean.
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28.
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Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
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29.
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Apply primer to all surfaces which have been ground clean. Use Standox 1K Füllprimer.
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30.
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Seal joints and metal folds with putty. Use Terostat 1K-PUR.
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31.
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Apply anti-corrosion agent to inside surfaces after painting. Use Terotex HV 400 or Mercasol 1.
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