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29.
30. Measure and mark out a section on the B-pillar upper, on
the vehicle as indicated.
CAUTION: Care should be taken not to cut through
into the inner panels.
NOTE: A drill bit suitable for drilling boron should be
used on the 4 upper boron spot welds.
Cut the section of the B-pillar upper at the points indicated
and drill out the spot welds.
31.
NOTE: Care should be taken when separating and removing the
section as it will be used as a template.
Carefully separate the section of the B-pillar upper and remove.
32. NOTE: Dress the panel joint surfaces of the template to make sure
it is a good fit.
Offer up, align and clamp the template into position on the new rocker
panel and B-pillar outer panel. Cut around the edge of the template,
through the new rocker panel and B-pillar outer panel at the points
indicated, where the MIG brazed butt joint is to be made.
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33. Remove the template from the new panel.
34. NOTE: This procedure shows the rocker panel part of the rocker
panel and B-pillar outer panel being installed to its service condition.
The rocker panel lower butt joints could be performed closer to the
B-pillar, dependant on the extent of the damage.
Using the new panel for reference and allowing for an overlap, cut the
old panel at the points indicated.
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36. Separate the joints and remove the bulk of the old panel.
Installation
1. CAUTION: Care should be taken not to cut through into the inner
panels.
NOTE: Temporarily install the front door and the rear door and
hinges, to aid alignment.
Offer up, align and clamp the new panel into position, overlapping the
old panel remnant. Cut through the new panel, partially cutting the old
panel at the points where the MAG butt joints are to be made.
2. Remove the front door and the rear door and hinges and the new rocker
panel and B-pillar outer panel.
3. Cut and remove the old panel remnants.
4. Drill holes in the new panel ready for MAG plug welding.
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6. NOTE: If necessary, renew the NVH component.
Prepare the old and new panel joint surfaces, including the NVH
component.
7. NOTE: Temporarily install the front door and the rear door and
hinges, to aid alignment.
Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not, rectify and recheck before
proceeding.
8. Remove the front door and the rear door and hinges and the new rocker
panel and B-pillar outer panel.
9. NOTE: Make sure the adhesive does not encroach into the
area of the butt joint as it will contaminate the weld (any
unsealed areas must be sealed following the repair).
Apply adhesive to the area as indicated.
10. Apply sealer adhesive to the NVH component as indicated.
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11. Offer up the new rocker panel and B-pillar outer panel, align and clamp
into position.
12. Tack MIG braze the upper butt joint.
13. Tack MAG weld the lower butt joints.
14. NOTE: Spot welds must be installed 5mm away from the originals
and in the same quantities, whenever this is possible. Where this is not
possible, spot welds should be installed adjacent to the original. Where
there is adhesive in the original joint, spot welds should be installed
through the original.
Spot weld.
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