Preparing New Parts

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• Release bonded rivet connections in the areas (1).

  Remove connecting plate (2).

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• Remove adhesive residue from bonding surfaces.
• Seal the hole (1) by MAG weld.
• Drill out holes (2) to dia. 6.8 mm.

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• Adjust new parts to fit with alignment bracket or universal mount and secure.
• Prepare reinforcement (1) in the area (2) for joining by welding.

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• Prepare areas (1) to (4) for structural bonding of steel on steel and of steel on aluminum.
• In the areas (1) and (2), drill out holes of diameter 6.8 mm and transfer to new part.
• In the area (3), transfer holes to both the new parts. Drill out holes to dia. 6.8 mm.
• In the area (4), drill holes of dia. 6.8 mm. Number and position of flow-drill screws as for series.

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• Prepare area (1) for structural bonding of steel on aluminum.
• In the areas (1), drill out holes of dia. 6.8 mm and transfer to new part.

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• Prepare areas (1) and (2) for structural bonding of steel on aluminum.
• In the areas (1) and (2) transfer hole pattern of wheel well on the spring support. Drill out holes to dia. 6.8 mm.

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• Prepare area (1) for structural bonding of steel on aluminum.
• In the areas (1), transfer hole pattern of engine bulkhead on the spring support. Drill out holes to dia. 6.8 mm.

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• Prepare the areas (1) for plug-welding.
• Weld the areas (1). Avoid excessive application of heat to adhesive area (2).

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• Prepare area (1) for structural bonding of steel on aluminum.
• In the areas (1), set 12 bores with Ø 6.8 mm on the new parts analogue to the standard production.
• Prepare areas (2) for structure bonding steel on steel.
• In the areas (2), set 2 bores with Ø 6.8 mm on the new parts analogue to the standard production.
• Prepare areas (3) and (4) for steel on steel structure bonding.
• In the areas (3) and (4), set 4 bores Ø 4.2 mm as shown.

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• Prepare the new part in the areas (1) for joining with MAG weld. The MAG weld seams have a length of = 15 mm.

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• Remove the adhesive residue in the areas (1).

• Prepare spot-welded adhesive joints for the series for joining by welding in the areas (1).
• Remove new parts and deburr bores.

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Check ground pins and replace if necessary 

• Check the ground pins (1) for stability and replace if necessary.

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