Replacing Front End Partially

1. Cut off end plate at body floor plate.

1. Cut off end plate at body floor plate.

The best method of repairing a damaged front end, of which the side members are bent or distorted in area of front axle or engine mounts, would not be replacing up to the deformation border, but complete replacement of side members and wheel houses at original connection points of floor or firewall.

These repairs can be best performed with help from the Celette straightening bench and pertinent attachment set ENS 243. 300 or front end gauge 9174,

These instructions apply to both one-side and two-side repairs.

2. Cut off wheel house wall and side member along firewall with a cutting wheel or pneumatic chisel.

Removing

Engine, transmission and front axle, radiator, headlights with motor and holders, fenders, covers and radiator grill, bumper with brackets and impact absorbers.

3. Cut off cross member and front lock carrier on damaged side, as long as only one side is being replaced.

Includes:

Front bumper, front side member, complete wheel house with reinforcement for spring strut, lock cross member and lower cross member.

4, Pull off scrap metal from wheel house and side member.

Porsche 928 Cross Member

5. Spot or inert gas weld wheel house along side 2. Position complete side member and bolt to member flange and firewall, all attachment take-up points.

Weld Side Member

3. Inert gas weld side member to floor plate and weld floor member on inside and outside all the way through.

6. Position lower cross member and lock cross member with help from attachments or front end gauge, tack weld and weld.

7, Install spring stmt console reinforcement, hold with attachment and inert gas weld to side member and wheel house.

9. Weld control arm console on inside of wheel house.

10. Position end plate with take-up shell on floor plate, clamp and tack weld.

Porsche 928 Cross Member Replacement

11. Position console for stabilizer on side member (295 mm from front cross member bolt, rear edge vertical) and weld to side member.

8, Line up top of console with wheel house and spring strut console, cut and weld.

11. Position console for stabilizer on side member (295 mm from front cross member bolt, rear edge vertical) and weld to side member.

Front Side Member Repair

12. Weld console for concealed headlight motor.

13, Apply prime coat paint and undercoating or sealing material to all welded seams and joints. Spray Tectyl sealant into cavities.

14. Position and mount fenders, headlights and engine hood.

15, Prepare car for painting.

Seam Sealant 755
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