Part of side panel, five-door body
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Part of side panel, five-door body
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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.
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Important
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The D pillar may be cut only as described below. If it is not, the reinforcement inside it could very likely be damaged.
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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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Cut the D-pillar 40 mm above the ball pin where the tailgate gas spring is attached.
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3.
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Cut the C pillar as shown.
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4.
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Drill out the spot welds.
Drill out the spot welds.
Drill out the spot welds.
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5.
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Knock loose the side panel and realign any deformed metalwork.
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6.
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Cut the spare part roughly to size to that it will overlap the joints by about three centimetres.
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7.
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Drill holes for plug welding in the spare part.
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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 joint can be welded edge-to-edge.
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10.
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Remove the spare part and use a grinder to clean the areas on the spare part and body that are to be welded.
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11.
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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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12.
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Position the spare part and fix it with a few welding clamps.
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13.
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Spot weld the spare part in place.
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14.
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Plug weld the spare part.
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16.
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Grind the welds clean.
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17.
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Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
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18.
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Apply primer to all surfaces that have been ground clean. Use Standox 1K Füllprimer.
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19.
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Seal joints and metal folds with putty. Use Terostat 1K-PUR.
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20.
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Apply anti-corrosion agent to the inside surfaces of the side panel after painting. Use Terotex HV 400 or Mercasol 1.
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