Partially prepare A-pillar for installation

AR63.20-S-1107-02P

Partially prepare A-pillar for installation

 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



000 588 02 84 00 Welder

WS60.00-P-0022K



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 new A-pillar outer section part (3) (areas A and B).

 Transfer separation points from vehicle.

2

Cut separating points on new A-pillar outer section part (3) (areas A and B).

 Commercially available devices/tools
Body power jigsaw

a

Dimension approx. 60 mm

b

Dimension approx. 120 mm

3

Cut off spot welds on new A-pillar outer section part (3) (areas C and D).

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

 Commercially available devices/tools
Spot weld milling machine

4

Cut off spot welds on new A-pillar outer section part (3) (area E).

 Commercially available devices/tools
Spot weld milling machine

5

Heat new A-pillar outer section part (3) in cross-hatched areas (areas F and G).

 Cross-hatched areas (areas F and G) are bonded.

6

Remove section from new A-pillar outer section part (3).

 New A-pillar outer section part (3) is multipiece.

7

Drill holes for MAG welding in A-pillar outer section (1) (areas H, I and J).

 Commercially available devices/tools
Hand drill

8

Punch holes for MAG welding in A-pillar outer section (1) (area K).

 Commercially available devices/tools
Hole punching pliers

9

Grind mating surfaces on A-pillar outer section (1) down to bare metal in crosshatched areas around holes.

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

 Commercially available devices/tools
Rotary wire brush

10

Remove shavings and drill chips.

 Commercially available devices/tools
Wet and dry vacuum cleaner

11

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

12

Punch holes for MAG welding in A-pillar reinforcement (2) (area N).

 Commercially available devices/tools
Hole punching pliers

13

Drill holes for MAG welding in A-pillar reinforcement (2) through one panel thickness (areas L and M).

 Commercially available devices/tools
Hand drill

14

Grind mating surfaces on A-pillar reinforcement (2) down to bare metal in cross-hatched areas around holes.

 Commercially available devices/tools
Rotary wire brush

15

A-pillar reinforcement (2)   (areas O and P).

16

Face-grind MAG spot welds (areas O and P).

 Commercially available devices/tools
Angular grinder

17

Grind mating surfaces on A-pillar reinforcement (2) down to bare metal (cross-hatched areas and area Q).

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

 Commercially available devices/tools
Rotary wire brush

18

Remove shavings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

19

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 surfaces with zinc dust paint (area Q).
Otherwise there may be adhesion problems.

 Observe pretreatment of bonding surface (area Q).