Preparation For Installation

(a) SPOT WELD POINTS

(1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding.

HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3 mm (0.12 in.).

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(b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER)

(1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer.

(c) MAKING HOLES FOR PLUG WELDING

(1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.

Thickness of welded portion

Size of plug hole

1.0 (0.04) under

5 (0.20) 0 over

1.0 (0.04) - 1.6 (0.06)

6.5 (0.26) 0 over

1.7 (0.07) - 2.3 (0.09)

8 (0.31) 0 over

2.4 (0.09) over

10 (0.39) 0 over

(d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS

(1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body.

(2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body.

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(e) ROUGH CUTTING OF JOINTS

(1) For joint areas, rough cut the new parts, leaving 20 -30 mm (0.79 - 1.18 in.) of overlap.

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