INSTALLATION PREPARATIONS

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Rough Cutting of New Parts

• For cut‐and‐join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} with the remaining area on the body side and then rough‐cut the new parts.

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Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO2 gas shielded‐arc welder to make the plug welds.

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Making Holes for CO2 Arc Welding

• For places that cannot be spot welded, make a hole for CO2 arc welding using a punch or drill as follows.

(mm {in})

Panel thickness (ø) | Hole diameter (ø)
--- | ---
0.60—0.90 {0.02—0.03} | 5 {0.19}
0.91—1.20 {0.04—0.05} | 6 {0.23}
1.21—1.80 {0.051—0.07} | 8 {0.31}
1.81—4.50 {0.071—0.17} | 10 {0.39}

• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates are put together. Also, weld the plates together tightly so that gaps do not develop.

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Application of Weld‐through Primer

• For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld‐through primer.

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