ROCKER PANEL(for Type B) CUT AND JOIN REPLACEMENT SECTIONS

B0083AF


  1. REMOVAL

    Symbol Meaning
    B00837V Remove Weld Points
    B00836T Remove Weld Points
    B00837Y Cut with Disc Sander etc.
    B00839L Cut and Join Location
    B00839F 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. Carefully cut the No. 3 inner pillar sub-assembly so not to damage A.

      B00839CC01
      *1 NO. 3 INNER PILLAR SUB-ASSEMBLY - -
      *a 95 mm (3.74 in.) *b 120 mm (4.72 in.)
      B0023UJ
      B00240N
      B00834LC01
      *A PATTERN 1 *B PATTERN 2
      B008355 Laser Screw Welding - -
      B0083ACC01
      *A PATTERN 1 *B PATTERN 2
      B008355 Laser Screw Welding - -

  2. INSTALLATION

    Symbol Meaning
    B00838T Spot Weld
    B008397 Plug Weld
    B00834Y Plug Weld
    B00839L Cut and Join Location
    B00837X Fillet Weld
    B0083AI 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.

      B00836HC01
      *1 NO. 3 INNER PILLAR SUB-ASSEMBLY - -
      *a 120 mm (4.72 in.) - -

    4. Before temporarily installing the new parts, weld the center body pillar reinforce sub-assembly lower and No. 3 inner pillar sub-assembly with the standard number of welding points.

      B00834FC01
      *1 CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER *2 NO. 3 INNER PILLAR SUB-ASSEMBLY

    5. Weld the center body pillar reinforce sub-assembly lower and NO. 3 inner pillar sub-assembly to the vehicle side.

      B0083AEC01
      *1 CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER *2 NO. 3 INNER PILLAR SUB-ASSEMBLY
      *a Ultra High Strength Steel Welding Point *b 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 18 Cyc.(0.27 Sec.)
        *b: 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.

      B00834JC01
      *A PATTERN 1 *B PATTERN 2
      *a Ultra High Strength Steel Welding Point - -
      B008355 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 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.

      B00834XC01
      *A PATTERN 1 *B PATTERN 2
      *a Ultra High Strength Steel Welding Point *b 15 mm (0.59 in.)
      B008355 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 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. Weld the rocker panel outer to the vehicle side.

      B00837QC01
      *1 ROCKER PANEL 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.

      B00242M

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

    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.