Spot And Plug Weld Nugget Size: Kia

Spot And Plug Weld Nugget Size: Kia

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 Kia has to say.

Kia provides their welding requirements in one central location in the body repair manual (BRM) under Body Repair – Body Panel Repair Procedure - General Information. This page is broken down into numerous sections. There are specific sections that highlight spot welding and MIG plug welding.

It is important to note that the Kia body repair manual states in the Determining a Welding Method section, “It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body be used when making repairs, try to use either spot welding or MIG plug welding. Do not braze any body components other than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.” Kia also provides a chart that determines what diameter plug weld hole is needed, depending on panel thickness.

Some key spot welding items from Kia are:

  • that it is the most reliable welding method.
  • when spot welding, increase the number of spot welds by 30% (1.3 times the original number of welds).
  • do not spot weld where it is thicker than 3 mm.

When using MIG plug welds, Kia states to:

  • use when spot welding can’t be done or spot welding is not necessary.
  • not exceed 1 mm of space between parts to be welded together.
  • use the same number of welds as the number of factory welds.

It is important to note that whether using spot welds or MIG plug welds, Kia specifies to, “Do a test welding on a piece of material of the same type and thickness as the part to be welded and proceed if the test welding is good.” Following OEM welding requirements, including what nugget size is required, will help ensure a complete, safe, and quality repair.

For additional Kia information, check out the Kia OEM Information page.

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