Important: The specific areas to be sectioned are determined by the extent of the damage to the vehicle. Sectioning should take place only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle.

1. Remove all panels and components necessary for access.
2. Restore as much of the damage as possible to factory specifications.
3. Remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

4. Locate the sectioning joint as necessary to replace the damaged portion of the door frame.



5. To section the front hinge pillar, measure down 80 mm (3¼ in) from the bottom of the large wiring harness holes in the hinge pillar.

Important: The reinforcement will be used as a backing plate.

6. Leave a gap of one and one half times the thickness of the metal.
7. Drill 8 mm (5/16 in) holes for plug welding.
8. Prepare all mating surfaces for welding as necessary.
9. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
10. Plug and stitch weld accordingly.



11. To section the center pillar, locate the sectioning joint 200 mm (8 in) down from the edge of the roof gutter (1), and mark a horizontal line.
12. Cut the door frame along this line for sectioning.
13. Perform additional sectioning procedures as necessary to remove damaged areas of the door frame opening.
14. Locate, mark and drill out all necessary factory welds. Note the number and location of welds for installation of the service panel.
15. Remove the damaged section of the door frame opening.

1. On the service part, mark a horizontal line to leave a gap of one and one-half times the thickness of the metal (2) at the sectioning joint.
2. Cut the service panel along this line.
3. Cut a 50 mm (2 in), piece from the unused portion of the service part for a backing plate.
4. To section the rocker panel area:

•	Cut a 100 mm (4 in) piece from the unused portion of the service part for a backing plate.

•	Remove the flange on each side of the backing plate so that it will fit behind the sectioning joint.

5. Drill 8 mm (5/16 in) holes for plug welding in the service part in the locations noted from the original panel.
6. Prepare all mating surfaces for welding as necessary.
7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
8. Drill holes for plug welding along the sectioning cut on the service part.
9. Locate these holes approximately 13 mm (½ in) from the edge of the sectioning cut.



10. Prepare the mating surfaces and position the backing plates with 25 mm (1 in) of the backing plate (1) exposed (leave 50 mm (2 in) exposed if sectioning the rocker panel area), and plug weld.
11. Position the service part to overlap the exposed portion of the backing plate.
12. Check fit using three-dimensional measuring equipment, and plug weld accordingly.
13. Stitch weld along the entire joint.
14. Make 25 mm (1 in) welds (1) along the seam with 25 mm (1 in) gaps between.
15. Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
16. Complete all other welds and sectioning procedures as necessary.
17. Clean and prepare all bare metal surfaces.
18. Apply the following as necessary:

•

Sealers.

•	Anti-corrosion materials.

•	Two-part catalyzed primer.

•

Top-coat.

Important: Do not combine paint systems. Refer to paint manufacturer's recommendations.

19. Install all panels and components previously removed for access.