- remove the front door;
- remove all hanging elements and components from the door;
- move the electrical wire harnesses to the side;
Figure 10.7. Places where the front door panel is cut when preparing it for installation: A - cutting point on the front side of the door glass frame
- prepare the front door panel for installation by using a sharp object to mark the cutting locations and using a grinding wheel to trim the door glass frame according to the drawing 10.7;
- use a power tool with a flexible abrasive disc to cut around the perimeter of B (figure 8) panel from the door. When cutting the door panel, be careful not to damage the base of the door;
Figure 10.8. Cutting the front door panel: A - the place where the door panel is cut from the front side of the door glass frame; B - places where the door panel was cut with a flexible abrasive disc; C - places of cutting with a hacksaw for metal
- use a hacksaw to cut the door panel at the base of the door glass frame in places C, shown in the figure 10.8;
- remove the panel from the front door;
- at the base of the door along the perimeter, at the base of the glass frame and the central longitudinal reinforcement, align, clean and straighten the surfaces to which the door panel will be adjacent;
- apply a layer of air-drying coating to all mating surfaces of the door base;
- install a new panel on the front door, making sure that where the door glass frame is cut off, the new door panel should overlap the glass frame;
- apply an air-drying coating to areas where metal overlaps;
Figure 10.9. Locations and profile of the edges of the new panel on the door base
- gradually and consistently, in several passes, flanging the edges of the new panel on the base of the door (figure 10.9);
- using carbon dioxide welding using the Kempe method, weld the overlapping sheets of metal at the base of the front door glass frame;
- along the perimeter of the door, in the places of flanging, additionally weld the panel at equal intervals using contact welding;
- use a power tool with an abrasive disc to clean the welds and flanging areas of the front door panel;
- to seal the door panel, apply a thin layer of sealing mastic around the perimeter of the door in the flanging areas using a brush;
- apply a protective coating to all exposed metal surfaces using an approved electrolytic galvanizing process;
- apply primer to the door panel and paint the door;
- install all hanging elements and units on the front door;
- install the front door.