ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

B0055VG


  1. REMOVAL

    Symbol meaning
    B0055SH Remove Weld Points
    B00560S Remove Weld Points
    B00561G Cut with Disc Sander etc.
    B0055W3 Cut and Join Location
    B0055UE 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. A is reused.

      B00561TN01
      B0055VVC03
      *a 270 mm (10.63 in.) *b 60 mm (2.36 in.)
      B0055XKC03
      *A w/o Rear No. 2 Seat *B w/ Rear No. 2 Seat
      *c 170 mm (6.69 in.) *b 185 mm (7.28 in.)
      B0055V3C01
      *a 80 mm (3.15 in.) - -

    3. 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.

      B0055QYC01
      B0055YJ Adhesive - -
      B0055ZI

  2. INSTALLATION

    Symbol meaning
    B0055QO Plug Weld
    B005608 Plug Weld
    B0055W3 Cut and Join Location
    B0055SN Fillet Weld
    B0055Y8 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.

      B0055ZRC01
      *1 CENTER BODY PILLAR SUB-ASSEMBLY INNER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
      *a 320 mm (12.60 in.) *b 60 mm (2.36 in.)

    4. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


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

      • Apply enough adhesive to the panels.

      B0055Q4C01
      B0055YJ Adhesive - -

    5. 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.

      B0055SXC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
      *3 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *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.

    6. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


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

      • Apply enough adhesive to the panels.

      B00560YC01
      B0055YJ Adhesive - -

    7. Weld the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar sub-assembly inner to the vehicle side.

      B0055U1C01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 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.

      B0055TEC01
      *1 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 10 mm (0.39 in.)
      *c 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.

    8. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


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

      • Apply enough adhesive to the panels.

      B0055X3C01
      B0055YJ Adhesive - -

    9. Weld the center body pillar outer and A to the vehicle side.

      B0055R8C01
      *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.

      B00560G

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

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