For 1990-2009 cars

Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.

Important: Only the outer longitudinal rail may be sectioned in the area specified. Repair and restoration of as much structure as possible before cutting and preparing joint for welding is imperative. No reinforcements may be sectioned! The rear longitudinal rail may be sectioned at this one place only (185 mm forward from rear edge of the longitudinal rail at the laser seam weld of rail). The reinforcement must be welded to the new rail section. This may be accomplished by using a screw to draw the two layers together. This hole will need to be welded when layers are attached.

1. Note amount and location of spot welds.
2. Remove the sealer and drill spot welds from the areas necessary to place a joint in the areas specified.

Important: To ensure a secure weld the sectioning joint should have a gap of approximately one and a half times the thickness of the metal. Trim the parts as necessary to achieve this.

3. Clean all weld seams with a wire brush. Prime and seal all repair areas.
4. Apply permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

5. Prime with two-part catalyzed primer.
6. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.

Important: Do not damage the inner reinforcements.

7. Cut the service part along the joint area.

Perform additional procedures as necessary to remove unused areas of the service part. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section. Clean surface for welding and grind ELPO primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 or equivalent to all areas to be welded. Stitch weld along the entire joint. Make 25 mm (1 in) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. Refer to "Space Frame Sectioning - General Notes" .