CENTER BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS

REMOVAL

Symbol Meaning
	Remove Weld Points
	Remove Weld Points
	Cut with Disc Sander etc.
	Cut and Join Location
	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. Be careful when cutting as foamed sealing material is located near the cutting position.

   

   Foamed Sealing Material

   -

   -

3. A is reused.

   

   *a	20 mm (0.79 in.)	*b	140 mm (5.51 in.)
   *c	260 mm (10.24 in.)	-	-

   

   *a

   175 mm (6.89 in.)

   -

   -

   

   

   *a

   20 mm (0.79 in.)

   -

   -

4. 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.

INSTALLATION

Symbol Meaning
	Plug Weld
	Plug Weld
	Fillet Weld
	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. Weld the center body pillar reinforce sub-assembly lower to the vehicle side.

   

   *1	CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER	-	-
   *a	12 mm (0.47 in.)	*b	15 mm (0.59 in.)

4. Apply adhesive (3M^TM Automix^TM Panel Bonding Adhesive #8115).

   Tip:

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

   • Apply enough adhesive to the panels.

   

   Adhesive

   -

   -

5. Weld the center body pillar reinforcement sub-assembly to the vehicle side.

   

   *1	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 1500 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. Be careful when welding as foamed sealing material is located near the area that is cut and joined together.

   

   Foamed Sealing Material

   -

   -

7. Apply adhesive (3M^TM Automix^TM Panel Bonding Adhesive #8115).

   Tip:

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

   • Apply enough adhesive to the panels.

   

   Adhesive

   -

   -

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

   

   *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 1500 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% + CO₂ 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO₂ shield gas.

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

10. After welding, apply body sealer 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.