ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

B003G20


  1. REMOVAL

    Symbol meaning
    B003FY5 Remove Weld Points
    B003G73 Remove Weld Points
    B003G52 Cut with Disc Sander etc.
    B003GAF 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. Remove the A.

      Tech Tips

      A is reused.

      B003FYAC01
      *a 60 mm (2.36 in.) - -
      B003G72 Laser Screw Welding - -

    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.

      B003G78C01
      B003G32 Adhesive - -

    4. Remove the center body pillar outer.

      B003GC0C01
      *1 CENTER BODY PILLAR OUTER - -
      *a 100 mm (3.94 in.) - -
      B003G72 Laser Screw Welding - -
      B003G95

    5. 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.

      B003G2LC01
      B003G32 Adhesive - -

    6. Remove the center body pillar reinforcement sub-assembly and rocker panel sub-assembly outer.

      B003G4VC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER PANEL SUB-ASSEMBLY OUTER
      *a 165 mm (6.50 in.) *b 135 mm (5.31 in.)
      *c 60 mm (2.36 in.) - -
      B003G72 Laser Screw Welding - -
      B003G4S

    7. When replace only the outer panel, please cut off a necessary range depending on a damage range.


      1. Carefully cut the outer panel so not to damage the reinforcement.

      2. Make sure that butt welding does not heat-affect the reinforcement when welding the outer panel.

  2. INSTALLATION

    Symbol Meaning
    B003G18 Plug Weld
    B003FYT Plug Weld
    B003GAF Cut and Join Location
    B003G3B Fillet Weld
    B003FZ0 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.

      B003FZ4C01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 165 mm (6.50 in.) *b 135 mm (5.31 in.)
      *c 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.

      B003FXIC01
      B003G32 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.

      B003FXKC01
      *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% + 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.

      B003G2LC01
      B003G32 Adhesive - -

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

      B003G16C01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER PANEL SUB-ASSEMBLY OUTER
      *a Ultra High Strength Steel Welding Point - -
      B003G72 Laser Screw Welding - -

        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% + CO220%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2shield gas.

      B003GBLC01
      *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 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% + 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.

      B003G78C01
      B003G32 Adhesive - -

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

      B003GAUC01
      *1 CENTER BODY PILLAR OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      B003G72 Laser Screw Welding - -

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

      • When welding 3 panels or more together including 1180 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.

    10. Weld the A to the vehicle side.

      B003G1RC01
      B003G72 Laser Screw Welding - -

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

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

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