ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

Info Added 2017-08-29

B000GPB


  1. REMOVAL

    Symbol Meaning
    B003XIE Remove Weld Points
    B003XJ5 Remove Weld Points
    B003XIL Cut with Disc Sander etc.
    B003XJ8 Cut and Join Location
    B003XIQ Cut Location for Supply Parts

    1. 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)

    2. Carefully cut the center body pillar reinforcement sub-assembly so not to damage A.

      B000GUJC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 70 mm (2.76 in.) *b 150 mm (5.91 in.)
      B000GQ1
      B000GIN
      B000GQ6

  2. INSTALLATION

    Symbol Meaning
    B000GHS Spot Weld
    B003XI7 Plug Weld
    B003XI6 Plug Weld
    B003XJ8 Cut and Join Location
    B003XIF Fillet Weld
    B003XJ7 Butt Weld

    1. Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

    2. Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimensions)

    3. If the entire supply part is not needed, remove the part of the supply part that is needed.

      B000GO9C01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 150 mm (5.91 in.) - -

    4. Before temporarily installing the new parts, weld the rocker reinforce sub-assembly outer, No. 6 lower outer rail sub-assembly and center body pillar reinforcement sub-assembly with the standard number of welding points.

      B000GHYC03
      *1 ROCKER REINFORCE SUB-ASSEMBLY OUTER *2 No. 6 LOWER OUTER RAIL SUB-ASSEMBLY
      *3 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a Ultra High Strength Steel Welding Point - -

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

      • When welding 2 panels together including 980 MPa ultra high strength steel.

        *a: Plug weld Plug diameter 10 mm (0.39 in.)
        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.

    5. Weld the rocker reinforce sub-assembly outer, No. 6 lower outer rail sub-assembly and center body pillar reinforcement sub-assembly to the vehicle side.

      B000GNRC01
      *1 ROCKER REINFORCE SUB-ASSEMBLY OUTER *2 No. 6 LOWER OUTER RAIL SUB-ASSEMBLY
      *3 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point

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

      • When welding 2 panels together including 980 MPa ultra high strength steel.

        *a: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 16 Cyc.(0.27 Sec.)
        *b: Plug weld Plug diameter 10 mm (0.39 in.)
        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.

      B000GNYC01
      *a Ultra High Strength Steel Welding Point *b 15 mm (0.59 in.)

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

      • When welding 2 panels together including 980 MPa ultra high strength steel.

        *a: Plug weld Plug diameter 10 mm (0.39 in.)
        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.

    6. Weld the center body pillar outer to the vehicle side.

      B000GR2C01
      *1 CENTER BODY PILLAR OUTER - -
      *a Ultra High Strength Steel Welding Point - -

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

      • 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.)

        *a: 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.

      B000GID

    7. After welding, apply the foamed sealing material to the corresponding parts. (See the painting/coating)

    8. After welding, apply body sealer to the corresponding parts. (See the painting/coating)

    9. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.