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Rough Cutting of New Parts

• For cut and join areas, allow for an overlap of 30—50 mm {1.2—1.9 in} with the remaining area on the body side and then rough cut the new parts.

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a gas shielded‐arc welder to make the plug welds.

Making Holes for Arc Welding

• For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows.

(mm {IN})

Panel thickness (φ)

Hole diameter (φ)

0.60—0.90 {0.024—0.035}
5.0 {0.20}
0.91—1.20 {0.036—0.047}
6.0 {0.24}
1.21—1.80 {0.0477—0.0708}
8.0 {0.31}
1.81—4.50 {0.072—0.177}
10.0 {0.394}
• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates are put together. Also, weld the plates together tightly so that gaps do not develop.

Cautions with Ultra-high Strength Steel Sheeting Repairs

• Because the ultra high-tensile steel is hard and it may be difficult to reform, when extracting the damaged part using a frame repair machine, perform the work verifying that other parts are not affected.
• When drilling welded parts, use a well-ground drill bit.
• Perform plug welding (arc welding).Do not perform continuous welding such as cut and join work as it may cause strength degradation.

Application of Weld‐through Primer

• For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld‐through primer.