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Contents Wiring diagrams Section: Side structure All sections

Replacement outer sill Peugeot 807 I

Side structure ~375 words

WarningThis vehicle has been designed using the mig brazing process technique; when repairing the structure, all the connections concerned must be welded using the same procedure; any other technique is prohibited

WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process

WarningObserve the elementary rules of hygiene and safety (wear a face mask to protect against fumes and vapour - work in a well ventilated space)

Complementary operation(s)

Removing - refitting

  • Front wing
  • Front door
  • The side sliding door
  • Sliding door bottom rail
  • Lower rear wing
  • Front and rear door aperture seals

Remove-refit trim

  • The centre pillar (lower part)
  • The rear pillar (lower part)
  • The a post (lower part)
  • The part floor

Parts required

(1) outer sill (specific repair parts)

Preparation of the new part

Mark then cut by means of a 1 mm grinder (final cut)

Mark out then drill 8 mm holes for later plug welding

Prepare the mating edges

Mark out then drill 8 mm holes for later plug welding

Prepare the mating edges

Cutting out

Mark then cut by means of a 1 mm grinder (at B)

WarningOn the a post, cut the first panel only

Cut out by milling out the spot welds

Cut out by milling out the spot welds

Cut out by milling out the spot welds

Remove

  • The outer sill
  • The b post and d post inflating inserts

Separating

Prepare the mating edges

Fit, and ensure that the inflating insert supports are in place

Adjustment

Fit

  • The outer sill
  • The front door
  • The front wing
  • The rear wing

Align the edges, even out the clearances

Remove

  • The rear wing
  • The front wing
  • The front door

Mark out the cuts

Remove the exterior longeron

Clean up the cuts

Prepare the mating edges

Protect the edges of the original and the new part with welding primer

Apply supporting structural adhesive (at C)

Apply sealing and welding mastic (at D)

Welding

MIG stitch weld (at E)

Grind the welds

Weld with electric spot welds

MIG plug weld

Grind the plug welds

MIG plug weld

Grind the plug welds

Finish

Lead load

Sealing

From underneath, apply finishing mastic

Protection

Apply an anti-chip layer

Spray liquid wax

Spray foam

  • Front pillar
  • Rear pillar

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