Partially cut off A-pillar

AR63.20-S-1107-01P

Partially cut off A-pillar

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A



000 588 00 84 00 Heat gun

WS54.00-P-0049B

Model

470, 471

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

1

Mark separating points on A-pillar outer section (1) (areas A and B).

2

Cut separating points on A-pillar outer section (1) (areas A and B).

 Do not make the cuts too deep.
Otherwise the components below can be damaged and weakened.

 Commercially available devices/tools
Body power jigsaw

a

Dimension approx. 60 mm

b

Dimension approx. 120 mm

3

Expose spot welds on A-pillar outer section (1) (areas C, D, E, F and G).

 Commercially available devices/tools
Rotary wire brush

4

Cut off spot welds on A-pillar outer section (1) (areas C, D, E, F and G).

 Cut off spot welds (arrows) through 2 panel thicknesses.

 Commercially available devices/tools
Spot weld milling machine

5

Remove bolt (3) .

6

Heat A-pillar outer section (1) in cross-hatched area (area H).

 Cross-hatched area is bonded (area H).

7

Remove A-pillar outer section (1).

8

Remove screws (4, 5).

9

Expose MAG spot welds (area I).

 Commercially available devices/tools
Rotary wire brush

10

Cut MAG spot welds (area I).

 Commercially available devices/tools
Angular grinder

11

Expose MAG weld seams (area J).

 Commercially available devices/tools
Rotary wire brush

12

Cut MAG weld seams (area J).

 Commercially available devices/tools
Angular grinder

13

Expose spot welds on A-pillar reinforcement (2) (area K).

 Commercially available devices/tools
Rotary wire brush

14

Cut off spot welds on A-pillar reinforcement (2) (area K).

 Commercially available devices/tools
Spot weld milling machine

15

Cut off heads of threaded pins (area L).

 Commercially available devices/tools
Angular grinder

16

Heat A-pillar reinforcement (2) in cross-hatched area (area M).

 Cross-hatched area is bonded (area M).

17

Remove A-pillar reinforcement (2).

18

Grind mating surfaces down to bare metal in cross-hatched areas.

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

19

Remove shavings and milling chips.

 Commercially available devices/tools
Wet and dry vacuum cleaner

20

Apply zinc dust paint to insides of spot weld flanges. onto connecting flanges that are no longer accessible after installing side roof paneling .

 Do not coat bonding surface with zinc dust paint (area N).
Otherwise there may be adhesion problems.

 Observe pretreatment of bonding surface (area N).

21

Grind mating surfaces down to bare metal in cross-hatched areas.

 Commercially available devices/tools
Rotary wire brush

22

Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner