ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

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)

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

Spot weld	Pressure	2940 N (300 kgf, 661 lbf)
	Weld current	10000 A
	Weld time	16 Cyc. (0.27 Sec.)
Plug weld	Plug diameter	10 mm (0.39 in.)
	Wire type	AWS A5.18 ER70S-3
	Shield gas	Metal active gas

*b: 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
	Cut with Disc Sander etc.
	Cut and Join Location
	Cut Location for Supply Parts

REMOVAL POINT

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)
Reuse *c, as the area of the outer panel that is cut and joined is in front of the supplied part cut position.
Reuse *d, as the area of the outer panel that is cut and joined is to the rear of the supplied part cut position.
Carefully cut the center body pillar reinforcement sub-assembly so not to damage *e.

mm (in.)

*1	CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY	-	-
*f	mm (in.)	-	-

mm (in.)

INSTALLATION

Symbol Meaning
	Remove Weld Points
	Spot Weld
	Plug Weld
	Cut and Join Location
	Fillet Weld
	Butt Weld

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)
If the entire supply part is not needed, remove the part of the supply part that is needed.
Carefully cut the center body pillar reinforcement sub-assembly so not to damage *c.
Follow the welding conditions when welding *a and *b to assure sufficient weld strength. (See the introduction)
Before temporarily installing the new parts, weld the rocker reinforce sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar reinforce sub-assembly lower with the standard number of welding points.
After welding the rocker reinforce sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar reinforce sub-assembly lower to the vehicle side, install the center body pillar outer, *d and *e.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.

*1	ROCKER REINFORCE SUB-ASSEMBLY OUTER	*2	CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
*3	CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER	-	-
*f	mm (in.)	-	-

mm (in.)

CENTER BODY PILLAR OUTER