Side_Door_Opening_Frame.pdf

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SIDE DOOR OPENING FRAME

When sectioning the door opening frame on the Camaro/Firebird convertible,

there are three locations where sectioning should not take place (figure 1).

Sectioning in these areas could jeopardize the structural integrity of the vehicle. The

door ring service panel is unique for convertibles. The panel can be installed as a

complete assembly or modified for sectioning. When sectioning in an area with

no reinforcement, a backing plate or sleeve must be used.

REMOVE OR DISCONNECT

1. Remove all related panels and components.

2. Visually inspect and restore as much damage as possible to factory

specifications.

3. Remove sealers, sound deadeners and corrosion materials, as necessary.

4. Locate, mark and drill out factory welds, as necessary. Note the number of

welds for installation of the new assembly.

5. Measure, mark, cut and remove the damaged section of the frame, being

careful in areas where there are multiple layers of steel.

n F IGURE 1 n

A REAS W HERE S ECTIONING

S HOULD N OT T AKE P LACE

1

CAMARO/FIREBIRD CONVERTIBLE COLLISION REPAIR ISSUES

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SIDE DOOR OPENING FRAME

INSTALL OR CONNECT

1. Prepare the new door opening

frame by measuring and cutting to

match the removed section. Check

for proper fit.

— NOTICE —

Do not section within 4 inches

(100 mm) of either inner lower

curve of the door opening frame or

outer rocker panel sectioning

(see figure 1).

— NOTICE —

A gap 1 1⁄2 times the thickness of

the metal must be maintained at

the joint between the old frame

and replacement frame (figure 2).

Trim the replacement frame, as

required, to achieve this fit.

1.5 times the

metal thickness

n F IGURE 2 n

F ITTING THE N EW P ANEL

2. In areas having no inner

reinforcements, cut pieces to serve

as backing plates of the same

configuration from the areas where

sectioning is to be done. These

should be approximately 3 inches

(75 mm) in length. Use the

damaged frame or the excess

portions of the replacement frame

(figure 3).

3. Modify the pieces so they fit snugly

to the backside of the section joints.

4. Pre-drill 5⁄16-inch plug weld holes

for installation of the new frame

(figure 4).

n F IGURE 3 n

F ITTING THE B ACKING P LATE

n F IGURE 4 n

P RE -D RILLING P LUG W ELD H OLES

2 CAMARO/FIREBIRD CONVERTIBLE COLLISION REPAIR ISSUES

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SIDE DOOR OPENING FRAME

n F IGURE 5 n

F ITTING THE B ACKING P LATE FOR W ELDING

5. Fit the backing plate halfway into

the section joint on the vehicle.

Clamp and MIG weld the backing

plate to the vehicle (figure 5).

6. When all the backing plates are

welded in place, reinstall the new

part and check the fit using body

dimensions.

7. When the replacement frame is

properly fitted and aligned, clamp

and MIG weld it to the backing

plates (figure 6). An alternating

weld sequence is recommended to

reduce heat and metal distortion.

8. MIG weld the remaining weld

holes to attach the panel

permanently (figure 7).

9. Clean and prepare welded

surfaces. Prime with two-part

catalyzed primer. Apply sealers

and corrosion protection materials,

as necessary. Do not combine

paint systems. Refer to paint

manufacturer’s recommendations.

Reinstall all related components.

n F IGURE 6 n

W ELDING THE J OINT G AP

n F IGURE 7 n

W ELDING THE R EMAINING H OLES

3

CAMARO/FIREBIRD CONVERTIBLE COLLISION REPAIR ISSUES

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