ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

K138029

  • With the front body pillar cut and join replacement sections (pattern 1) removed.

  1. REMOVAL

    Symbol Meaning
    K108818

    Remove Weld Points
    K108820

    Remove Weld Points
    K108826

    Cut with Disc Sander etc.
    K108827

    Cut and Join Location
    K108828

    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 center body pillar reinforcement sub-assembly so not to damage A.

      K137872C01

      *1

      CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY

      -

      -

      *a

      70 mm (2.76 in.)

      *b

      150 mm (5.91 in.)
      K137873
      K137874
      K137875

  2. INSTALLATION

    Symbol Meaning
    K108821

    Spot Weld
    K108823

    Plug Weld
    K108825

    Plug Weld
    K108827

    Cut and Join Location
    K108830

    Fillet Weld
    K108831

    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.

      K137876C01

      *1

      CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY

      -

      -

      *a

      150 mm (5.91 in.)

      -

      -

    4. Before temporarily installing the new parts, weld the rocker reinforce sub-assembly outer, No. 6 lower outer rail sub-assembly and center body pillar reinforcement sub-assembly with the standard number of welding points.

      K137877C03

      *1

      ROCKER REINFORCE SUB-ASSEMBLY OUTER

      *2

      No. 6 LOWER OUTER RAIL SUB-ASSEMBLY

      *3

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

    5. Weld the rocker reinforce sub-assembly outer, No. 6 lower outer rail sub-assembly and center body pillar reinforcement sub-assembly to the vehicle side.

      K137878C01

      *1

      ROCKER REINFORCE SUB-ASSEMBLY OUTER

      *2

      No. 6 LOWER OUTER RAIL SUB-ASSEMBLY

      *3

      CENTER BODY PILLAR REINFORCEMENT 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

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

      K137879C01

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

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

      K137880C01

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

      K137881

    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.