ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS (LARGE AREAS)

A00256D

    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. *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
    Wire type Metal active gas

  2. *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.


  1. REMOVAL

    Symbol Meaning
    A002563 Remove Weld Points
    A0025AX Remove Weld Points
    A0025C9 Cut with Disc Sander etc.
    A0025I7 Cut and Join Location
    A002561 Cut Location for Supply Parts

      REMOVAL POINT

    1. Do not butt weld or heat repair because the heat decreases the strength of areas where ultra highstrength steel is used. (See the introduction)

    2. *c in the illustration indicates the laser screw welding location.

    3. Reuse A, as the area of the outer panel that is cut and joined is in front of the supplied part cut position.

    4. After removing the quarter panel, remove the rocker panel sub-assembly outer.

    5. *d in illustration indicates where the adhesive is located.

    6. Roughly cut open the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel.

      Tech Tips

      In cases where the adhesive cannot be removed with a cut chisel, heat the adhesive with an industrial heater gun or gas burner taking care not to cause panel deformation by overheating.

    7. Carefully cut the center body pillar reinforcement sub-assembly so not to damage B.

    8. Carefully cut the rocker panel sub-assembly outer so not to damage C.

    A0025HRC01
    *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
    *e 260 mm (10.24 in.) *f 155 mm (6.10 in.)
    A0025GD Laser Screw Welding - -
    A0025G8C01
    *1 ROCKER PANEL SUB-ASSEMBLY OUTER - -
    *e 100 mm (3.94 in.) *f 170 mm (6.69 in.)
    *g 110 mm (4.33 in.) *h 40 mm (1.57 in.)
    A0025GD Laser Screw Welding - -
    A0025GQC01
    *1 QUARTER PANEL *2 ROCKER PANEL SUB-ASSEMBLY OUTER
    *e 310 mm (12.20 in.) *f 90 mm (3.54 in.)
    A0025GD Laser Screw Welding - -

  2. INSTALLATION

    Symbol Meaning
    A002563 Remove Weld Points
    A00258K Spot Weld
    A0025D7 Plug Weld
    A0025EP Plug Weld
    A0025I7 Cut and Join Location
    A0025EA Fillet Weld
    A0025BS Butt Weld

      INSTALLATION POINT

    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. *c in the illustration indicates the laser screw welding location.

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

    5. A is reused.

    6. Carefully cut the rocker panel sub-assembly outer so not to damage B.

    7. Carefully cut the center body pillar reinforcement sub-assembly so not to damage C.

    8. Follow the welding conditions when welding *a and *b to assure sufficient weld strength. (See the introduction)

    9. Before temporarily installing the new parts, weld the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar sub-assembly inner with the standard number of welding points.

    10. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115) to the area indicated by *d in the illustration.

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

    11. After welding the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar sub-assembly inner to the vehicle side, install the D.

    12. After welding the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly, center body pillar sub-assembly inner and D to the vehicle side, install the center body pillar outer, quarter panel and E.

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

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

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

    A0025FIC01
    *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
    *3 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
    *e 80 mm (3.15 in.) *f 135 mm (5.31 in.)
    *g 40 mm (1.57 in.) *h 90 mm (3.54 in.)
    *i 165 mm (6.50 in.) - -
    A00258FC01
    *e 10 mm (0.39 in.) *f 20 mm (0.79 in.)
    A0025GD Laser Screw Welding - -
    A0025C3C01
    A0025GD Laser Screw Welding - -
    A0025FCC01
    *e 20 mm (0.79 in.) *f 15 mm (0.59 in.)
    A0025GD Laser Screw Welding - -
    A00255DC01
    *1 CENTER BODY PILLAR OUTER - -
    A0025GD Laser Screw Welding - -
    A002592C01
    *1 QUARTER PANEL - -
    A0025GD Laser Screw Welding - -