FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS

With the cowl top side upper panel and cowl top side panel removed.

Weld work for 980 MPa ultra high strength steel

Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength. (When repairing this model)

*1: When welding 2 panels together including 980 MPa ultra high strength steel.

Plug weld	Plug diameter	10 mm (0.39 in.)
	Wire type	AWS A5.18 ER70S-3
	Shield gas	Metal active gas

*2: When welding more than 3 panels together including 980 MPa ultra high strength steel. (When plug welding a third panel to 2 panels which are welded under the conditions described above.)

Plug weld	Plug diameter	Same as the standard method (See the introduction)
	Wire type	AWS A5.18 ER70S-3
	Shield gas	Metal active gas

Note

Be sure to use Metal active gas (Ar 80% + CO₂20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO₂shield gas.

REMOVAL

Symbol meaning
	Remove Weld Points
	Remove Weld Points
	Remove Weld Points
	Cut with Disc Sander etc.
	Cut and Join Location

REMOVAL POINT

*4 is reused.
Do not butt weld or heat repair because the heat decreases the strength of areas where ultra high strength steel is used. (See the introduction)
*3 indicates welds to remove for easier removal.

INSTALLATION

Symbol meaning
	Plug Weld
	Plug Weld
	Plug Weld
	Fillet Weld
	Butt Weld
	Body Sealer

INSTALLATION POINT

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimensions)
Before installing a new part, apply body sealer.

Tech Tips

Apply body sealer in an even, continuous bead.
Follow the welding conditions when welding *1 and *2 to assure sufficient weld strength. (See the introduction)
When welding *3, make a hole on a new part for plug welding and weld the panel with the panel behind completely.
After welding the cowl side panel sub-assembly to the vehicle side, install the front body pillar reinforce sub-assembly lower.
After welding the front body pillar reinforce sub-assembly lower to the vehicle side, install the front body pillar outer and *4.
After welding, apply the foamed sealing material to the corresponding parts. (See the painting / coating)
After welding, apply body sealer to the corresponding parts. (See the painting / coating)
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.