Mazda 5. Manual — part 65
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–23
09
End Of Sie
FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL
DPE098053300B03
1. Rough cut and remove the damaged part of the front side frame.
3
4
9
10
FRONT SIDE FRAME COMPONENT
DPE0980B065
09–80B–24
BODY STRUCTURE [PANEL REPLACEMENT]
End Of Sie
FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION
DPE098053300B04
Caution
• The cut-and-joint area indicates the maximum size range of the installation position.
1. Make a reinforcement panel using the material from the front side frame.
2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and
chamfer the joint surfaces of the new and existing parts.
3. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform
with standard dimensions.
130mm
{5.12in}
40mm
{1.57in}
5
6
240mm
{9.45in}
40mm
{1.57in}
FRONT SIDE FRAME
ROUGH CUT
LOCATION (INNER)
ROUGH CUT
LOCATION (OUTER)
CUT-AND-JOIN
LOCATION (OUTER)
CUT-AND-JOIN
LOCATION (INNER)
DPE0980B074
BODY STRUCTURE [PANEL REPLACEMENT]
09–80B–25
09
4. To install the inner, trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then
butt weld the new and existing parts.
5. Because the outer cannot be welded to the existing parts from the inside of the frame, drill 2 plug weld holes at
the locations indicated by (A) on the existing parts. Install the reinforcement and the existing parts by plug
welding from the outside of the frame, then butt weld the new and existing parts.
Caution
• Press fit the reinforcement panel and the body side material, and then plug weld them.
6. Grind the area where the inner and outer are butt welded with a disc grinder to finish the surface.
REINFORCEMENT
REINFORCEMENT
65mm
30mm
OUTER:t=2.0mm
INNER:t=2.0mm
L=10mm x 2
L=10mm x 6
{0.39in}
{0.39in}
{0.08in}
{0.08in}
{1.18in}
{2.56in}
240mm
{9.45in}
CUT-AND-JOIN
LOCATION (INNER)
FRONT SIDE FRAME
FRONT SIDE FRAME
(INNER)
NEW FRONT SIDE FRAME (INNER)
DPE0980B075
09–80B–26
BODY STRUCTURE [PANEL REPLACEMENT]
End Of Sie
TORQUE BOX REMOVAL
DPE098053381B01
1. Drill the 2 locations indicated by (A) from the interior.
2. Remove the torque box.
130mm
{5.12in}
{0.39in}
(A)2
5
6
L=10mm x 2
FRONT SIDE FRAME (OUTER)
NEW FRONT SIDE FRAME (OUTER)
CUT-AND-JOIN
LOCATION (OUTER)
REINFORCEMENT
DPE0980B076
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