Front Hinge Pillar Body Replacement Corvette

The front hinge pillar panel is bolted, welded and bonded with structural adhesive to the side structure and frame rail. The replacement front hinge pillar panel is serviced as an assembly. You must remove and replace the side door opening panel in order to replace the front hinge pillar.

Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Note the location of the sealers and the anti-corrosion materials and remove these components from the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair.



6. Remove the bolts (1) attaching the front hinge pillar to the windshield frame.




Note: Do NOT damage the inner panels or the reinforcements.

7. Locate and remove all factory welds (1) from the outer hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.



8. Locate and remove all factory welds (1) from the inner hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.



9. Remove the damaged hinge pillar.
10. Note the location of the adhesive and remove all remaining loose adhesive.

1. Before applying the adhesive, dry fit the hinge pillar for proper fit and alignment.
2. Prepare all welding attachment surfaces as necessary.

Note: Use primer only on bonding surfaces. Do NOT top coat any bonding surfaces. Refer to the adhesive manufacture's recommendation.

3. Clean and prepare all bonding mating surfaces according to the adhesive manufacturer's recommendations.
4. Apply a consistent bead of structural adhesive 10 mm (3/8 in) in diameter to mate with the bonding surfaces. Refer to Sheet Molded Compound (SMC) Panel Bonding.



5. If the weld (1) is not accessible, replace the weld with structural adhesive.
6. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.



7. Position the hinge pillar to the vehicle using 3-dimensional measuring equipment.

Caution: Refer to Fastener Caution in the Preface section.

8. Install the bolts (1) that attach the windshield frame to the front hinge pillar and tighten to 25 N·m (18 lb ft).



9. Using a metal inert gas (MIG) welder, stitch weld the inner hinge pillar to the vehicle in the locations (1) noted on the original panel.



10. Using a MIG welder, stitch weld the outer hinge pillar to the vehicle in the locations (1) noted on the original panel.
11. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install all related panels and components.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
15. Enable the SIR system. Refer to SIR Disabling and Enabling.

Front Hinge Pillar Body Replacement Z06, ZR1

Note: When welding cast aluminum recommend wire alloy is 4043 and the recommend wire size is 0.035. The shielding gas is 100 percent Argon.

The front hinge pillar panel is bolted, welded, and bonded with structural adhesive to the side structure and frame rail. The replacement front hinge pillar panel is comprised of two types of materials. These include 6063 aluminum for the upper panel and A356 cast aluminum for the lower panel. You must remove and replace the side door opening panel in order to replace the front hinge pillar.

Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Note the location of the sealers and the anti-corrosion materials and remove these components from the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair.



6. Remove the bolts (1) attaching the front hinge pillar to the windshield frame.




Note: Do NOT damage the inner panels or the reinforcements.

Note: Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.

7. Locate and remove all factory welds (1) from the front outer hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.



8. Locate and remove all factory welds (1) from the rear outer hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.



9. Locate and remove all factory welds (1) from the inner hinge pillar. Note the number and location of the welds for installation of the new hinge pillar.



10. Remove the damaged hinge pillar.
11. Note the location of the adhesive and remove all remaining loose adhesive.

1. Before applying the adhesive, dry fit the hinge pillar for proper fit and alignment.

Note: Use primer only on bonding surfaces. Do NOT top coat any bonding surfaces. Refer to the adhesive manufacture's recommendation.

2. Clean and prepare all bonding mating surfaces according to the adhesive manufacturer's recommendations.
3. Apply a consistent bead of structural adhesive 10 mm (3/8 in) in diameter to mate with the bonding surfaces. Refer to Sheet Molded Compound (SMC) Panel Bonding.



4. Position the hinge pillar to the vehicle using 3-dimensional measuring equipment.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the bolts (1) that attach the windshield frame to the front hinge pillar and tighten to 25 N·m (18 lb ft).

Note: Use a stainless steel brush to remove the oxide layer prior to welding.

6. Prepare all welding attachment surfaces as necessary.

Note: Recommend wire alloy is 4043 and wire size is 0.035. The shielding gas is 100 percent Argon. A 2 minute cooling down period is recommend for every 2 minutes or 100 mm (4 in) of welding.

7. Using a PULSED-MIG welder, tack weld the hinge pillar to the vehicle.



8. Using a PULED-MIG welder, stitch weld the front outer hinge pillar to the vehicle in the locations noted on the original panel.



9. Using a PULED-MIG welder, stitch weld the rear outer hinge pillar to the vehicle in the locations noted on the original panel.



10. Using a PULED-MIG welder, stitch weld the inner hinge pillar to the vehicle in the locations noted on the original panel.
11. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install all related panels and components.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
15. Enable the SIR system. Refer to SIR Disabling and Enabling.