Front Bulkhead Installation

  1. Cut the new front side frame and backplate to align them with the body.
  1. Align the holes of the front side support (A) to the bumper beam mount hole of the front side frame (B), and weld the front side support and side frame.
  1. Align the holes of the bumper extension outer bracket (A) and backplate (B), and tack weld the bumper extension outer bracket.
  1. Attach the patch (A) at the cut section (B), set the new front side frame (C) and backplate (D), and tack weld them.
  1. Clamp the new side frame gusset (A), and check the body dimensions.
  1. Weld the new front side frame (A), backplate (B), and side frame gusset (C).
  1. Set the new parts bulkhead and, measure the front compartment diagonally.
  1. Check the body dimensions.
  1. Tack weld the new parts into position.
  1. Temporarily install the hood, front fender, headlight, and front bumper, then check for differences in level and clearance.
  1. Do the main welding.
    • Weld the front side frame (A) and bulkhead side stay (B).
    • Weld the front side support (C) and bulkhead side stay.
  1. Remove the bulkhead upper center frame (A). Weld the bulkhead side stay (B) and bulkhead upper side frame (C).
  1. Weld the bulkhead upper side frame (A) to the front wheelhouse lower extension (B), and install the bulkhead upper center frame (C).