Spot And Plug Weld Nugget Size: Ford/Lincoln

Spot And Plug Weld Nugget Size: Ford/Lincoln

Did you know that many OEMs specify nugget size for spot and plug welds? This information is typically found within vehicle-specific repair procedures or can be found under general welding guidelines. Let’s see what Ford/Lincoln has to say.

Ford/Lincoln provides a Weld Nugget Chart within vehicle-specific body repair manuals. This chart provides the configurations of different metal thickness to be joined and the corresponding spot weld nugget diameter. Nugget size is not based just on total metal thickness, but the layering of the metal as well. It is important to reference and follow the Weld Nugget Chart to help ensure a solid weld.

The Ford Recommended Steel Repairability Matrix which is also found in the vehicle-specific body repair manuals, typically found in section “501-25 Body Repairs - General Information”, specifies which types of steel can be spot or plug welded. The chart also provides temperature range and maximum heat.

Ford/Lincoln also states in the Welding Precautions section:

  • Replace spot-welded components by spot welding where possible.
  • Factory spot welds may be substituted with either STRW or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Following OEM welding requirements, including what nugget size is required, will help ensure a complete, safe, and quality repair.

For additional Ford/Lincoln information, check out the following pages:
Ford OEM Information
Lincoln OEM Information

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