The following photographs all show a car shell before finishing work is
carried out.
Therefore finishing details and fittings are not show.
Before starting the actual work, cover up or remove all fittings, cables, pipes and
hoses which may be burnt.
Take off all accessories or other parts that have been fitted onto the bodywork.
Jach up car.
On BMW 2800 CS adjust underfloor support frame to fit car body. This frame can be
adjusted in both directions to fit.

Remove both side panels on front.
Mark partition lines in wheel arch with chalk.

Mark partition lines in upper section of wheel arch with chalk.
Do not cut through pipe (A). This pipe is welded into the splasboard.

Cut off front body section at marked lines by means of a cutting torch without
a kick-back effect.

Grind edges of cut to ensure smooth surface.
Pull spot welding points off splashboard.
Cut off heater partition at fastening catch for engine compartment lock.

Screw on frame support at bearing points for final drive and final drive
support - with the frame support hinged down at the front.

Force the cut-off engine supports into each other, hammer to original shape
from the bottom corresponding to overlapping and press together slightly at sides.

Check thread for fastening front axle in front body section and cut thread anew
with tap if necessary (M 12 x 1.5).

Place front body section on frame support and fit in position to rest of
bodywork.
Cut off connecting member on cowl panel und cut off clamp support for engine
compartment lock.

To check, raise frame support at front. In so doing the carrier for the front axle
support must be parallel to the frame support and have no tension.

Make engine mounts overlap, fit them in position and align with hammer
so that both sections rest on each other. Weld slightly (spot welding). In so
doing press sections together on the side by means of a screw clamp.

Weld engine mounts all round applying electric welding method.
Type T electrodes: Use Vlls viscous for thin metal sheet welding.
Weld engine mount on floor panel applying autogenous welding method.

Pull front body section lightly onto the partition panel, so that both
partition surfaces rest on each other. Use a hydraulic pulling apparatus for this
purpose.
The hose for the spring struts in the front body section and the holes for the
spring in the frame support must be in flush.
Place spacer gauge in the spring strut supports.

Connect front section at all edges by spot welding slightly (autogenous
method).

To finish welding on front body section, hinge frame support down.
Fill up welding seam between splashboard and spring strut reinforcement with
hard solder.
Weld panel supporting the door lock lightly onto the door column and wheel arch
and weld on securely using spot welder.
Make two rows of spots, with a gap of 15 ÷ 20 mm (0.6 ÷ 0.8") between the
welding spots.
Dia. of electrode: 4 mm (0.15748").

Weld on front body section below cowl panel using spot welder.

Weld front body section onto splashboard using spot welder.

Cover welding seams and spots with two-component prime layer paint and
spray on underfloor protective cover.
Put on sheet metal nuts.

To check, hold side panel in position (door slit).

Fit on side panels, cf. 41 35 000.
Fit on engine compartment lid.
Adjust the slit between the engine compartment lid and the cowl panel after having
loosened hinge fastening bolts (B). (A = approx. 5 ÷ 6 mm/0.19685 ÷ 0.23622").
Adjust the slit between the engine compartment lid and the side panel by moving
side panel to and fro. (Slit = approx. 5 ÷ 6 mm/0.19685 ÷ 0.23622").
Tighten side panel and hard-solder at front and bottom (C).
After having loosened hinge fastening bolts (D) adjust height of engine
compartment lid in such a way that it is flush (i.e. same height) with the side panels.


41 35 000