Partially weld in A-pillar

AR63.20-S-1107-03P

Partially weld in A-pillar

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 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

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX



000 588 01 84 00 Welder

WS60.00-P-0021K



000 588 02 84 00 Welder

WS60.00-P-0022K

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

BR00.45-Z-1001-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 35 97

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71

1

Install, fit A-pillar reinforcement (2) and fix in place with  side portal frame, welding fixture and screws (3, 4).

 Commercially available devices/tools
Clamping pliers (Standard)

2

Drill rivet holes in A-pillar reinforcement (2) with Ø 6.5 mm (area A).

 Commercially available devices/tools
Hand drill

3

Remove bolts (3, 4).

4

Remove A-pillar reinforcement (2) and welding fixture.

5

Deburr rivet holes (area A) on both sides.

6

Coat insides of the riveted joints and rivet holes with zinc dust paint.

7

Apply 2-component adhesive to the body (area B).

 Observe pretreatment of bonding surfaces (area B). Observe manufacturer's specifications for curing and processing times of 2-component adhesive.

8

Install and fit A-pillar reinforcement (2) and fix in place with welding fixture and screws (3, 4).

 Commercially available devices/tools
Clamping pliers (Standard)

9

A-pillar reinforcement (2)   (areas C, C1, D and E).

10

A-pillar reinforcement (2)   (area F).

11

Rivet A-pillar reinforcement (2) with rivets with a diameter of 6.4 x 14 (area G).

 Commercially available devices/tools
Blind rivet gun (minimum pull-off force 19 kN)

12

Remove welding device.

13

Face-grind spot welds (areas C, C1, D and E).

 Commercially available devices/tools
Angular grinder

14

Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

15

Apply sealant (area H).

16

Clean areas that are no longer accessible after installing the A-pillar outer section (1) and coat with zinc dust paint.

17

Install, fit A-pillar outer section (1) and fix in place with  side portal frame, welding fixture and screw (6).

 Commercially available devices/tools
Clamping pliers (Standard)

18

A-pillar outer section (1)   (areas I, J and K).

19

A-pillar outer section (1)   (areas L, M and N).

20

Remove welding device.

21

Face-grind inert gas spot welds (areas L, M and N).

 Commercially available devices/tools
Angular grinder

22

A-pillar outer section (1)   (areas O and P).

 Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

23

Grind inert gas welds down flat (areas O and P).

 Commercially available devices/tools
Angular grinder

24

Clean weld joints.

 Commercially available devices/tools
Rotary wire brush

25

Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

26

Repair and smooth surfaces on A-pillar outer section (1) (areas O and P).

 Different methods can be used to restore the surfaces.