Chevrolet Silverado / GMC Sierra. Service manual - part 1284

Fig. 56: Grinding Outer Door Panel Edges 
Courtesy of GENERAL MOTORS CORP. 

1. Using a grinding disk grind the surface of the door shell mating flanges to bare steel. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Fig. 57: Scuffing Mating Surfaces 
Courtesy of GENERAL MOTORS CORP. 

2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Fig. 58: Drilling Plug Weld Holes 
Courtesy of GENERAL MOTORS CORP. 

3. Drill 8 mm (5/16 in) plug weld holes, as necessary, in the locations noted from the original panel. 

IMPORTANT: In any area damaged beyond recognition, space plug weld holes every 40 

mm (1 in) apart.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

4. Clean the mating surfaces. 

Fig. 59: Applying Metal Panel Bonding 
Courtesy of GENERAL MOTORS CORP. 

5. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces.  

6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure 

corrosion protection.  

7. Apply a 9-13 mm (3/8-1/2 in) bead of metal bonding adhesive to the mating surfaces of the service panel. 

IMPORTANT: Do not allow the door to totally cure off the vehicle, as proper alignment 

of the door outer panel to the door shell will be difficult.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado