Visually inspect and restore as much of the damage as possible to factory
specifications.
Remove the following as necessary:
•
Sealers
•
Sound deadeners
•
Anti-corrosion materials
Note the number and location of welds for installation of the new rail.
Separate the floor pan reinforcement vertical
flange from inside the lower rail. Care must be taken not to damage the flange.
Drill out factory welds along the lower flange on the floor pan reinforcement.
Note that the flanges overlap the rails (1).
Turn the lower flange down on an angle away from the rail.
Drill out the remaining factory welds on
the rail.
The lower portion of the wheelhouse at the rail must also be drilled
out and removed.
With a flat chisel, loosen the adhesive (2) between the floor pan and
lower rail (1) by prying the rail away from the floor. Care must be taken to avoid
damaging the floor.
Prepare mating surfaces for proper fit of the new rail.
Turn the vertical flange forward to be
welded to the new rail.
Drill the same number of 8 mm (5/16 in) holes on the new
rail in the remaining locations as noted from the original rail.
Position the new rail in place and check for proper alignment.
Remove the rail to clean and prepare all surfaces.
Prime surfaces in the same locations as the original adhesive using PPG
DP40 or an equivalent primer.
Apply GM Goodwrench structural bonding epoxy P/N 12345726 to the
rail in the same location as the original adhesive.
Position the new rail in place and secure.
With the new rail in place, reposition the down-turned flange to the
original location (1).
Plug weld in a random formation until all welding is completed.
Clean and prepare welded surfaces.
Apply sealers and anti-corrosion materials as necessary.
Apply sound-deadening materials to restore sound deadening quality as
manufactured. Use Dominion Sure Seal Paintable Sound Deadening Pads P/N 110900,
or equivalent.
