ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A004D2V


  1. REMOVAL

    Symbol meaning
    A004D0P Remove Weld Points
    A004CVQ Cut with Disc Sander etc.
    A004D1P Cut and Join Location

    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. 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.

      A004CW1C01
      A004D5G Adhesive - -
      A004D04C01
      *a 25 mm (0.98 in.) - -
      A004CYF

  2. INSTALLATION

    Symbol Meaning
    A004D2M Plug Weld
    A004D1P Cut and Join Location
    A004D1L Fillet Weld
    A004D16 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.

      A004CWVC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 25 mm (0.98 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.

      A004D5WC01
      A004D5G Adhesive - -

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

      A004CWFC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER PANEL SUB-ASSEMBLY 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 2 panels together including 1180 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield 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.

      A004CW1C01
      A004D5G Adhesive - -

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

      A004CY5C02
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER PANEL SUB-ASSEMBLY OUTER
      *a Ultra High Strength Steel Welding Point *b 10 mm (0.39 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 1180 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

      A004D00C01
      *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 1180 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

    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.