- remove the front door;
- remove all attachments and components from the door;
- set aside the electrical wiring harnesses;
Pic. 10.7. Places for trimming the front door panel when preparing it for installation: A - cutting point on the front side of the door glass frame
- prepare the front door panel for installation, for which mark the cutting points with a sharp object and cut the door glass frame with a grinding wheel in accordance with fig. 10.7;
- with an electric tool with a flexible abrasive disc, cut around the perimeter B (pic. 8) door panel. When cutting the door panel, take care not to damage the base of the door;
Pic. 10.8. Cutting the front door panel: A - the place of cutting the door panel from the front side of the door glass frame; B - places for cutting the door panel with a flexible abrasive disc; C - places for cutting with a hacksaw
- use a hacksaw to cut the door panel at the base of the door glass frame at locations C shown in fig. 10.8;
- remove the panel from the front door;
- on the base of the door along the perimeter, at the base of the glass frame and the central longitudinal reinforcement, align, clean and straighten the surfaces to which the door panel will adjoin;
- on all mating surfaces of the door base, apply a layer of air-drying coating;
- install a new panel on the front door, at the same time, in the places where the door glass frame is cut, the new door panel should overlap the glass frame;
- in places of metal overlap, apply a coating that dries in air;
Pic. 10.9. Locations and profile of the edging of the new panel on the door base
- gradually and consistently, in several passes, bead the edges of the new panel on the door base (pic. 10.9);
- carbon dioxide welding according to the Kempe method, weld sheets of metal overlapping each other at the base of the front door glass frame;
- along the perimeter of the door, in the places of flanging, additionally weld the panel at regular intervals by resistance welding;
- with an electric tool with an abrasive disc, clean the places of welding and flanging of the front door panel;
- to seal the door panel, apply a thin layer of sealing mastic along the perimeter of the door, in the places of flanging with a brush;
- Protect all bare metal surfaces using an approved electro-galvanizing process
- primer the door panel and paint the door;
- install all attachments and assemblies on the front door;
- install the front door.