Steel Spot And Plug Weld Nugget Size: Toyota/Lexus - UPDATE

Did you know that some 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 Toyota/Lexus has to say.

Toyota/Lexus provides their welding requirements in one central location in each vehicle-specific body repair manual (BRM). After you have logged into the subscription website and entered the vehicle information:

1. Click on the CR (Collision Repair) tab
2. Click on 6. Introduction: Work Notices and Precautions: Precautions For Welding

This page is broken down into numerous categories. You will want to scroll down and review the Welding Work area that highlights what to do when welding two or more steel panels together, including ultra-high-strength steel (UHSS). This area will specify the type of welding wire and shielding gas to be used.

Spot Welding

Toyota/Lexus does not indicate a specific plug weld nugget size in their collision repair information.

The spot welding area:

• specifies the number of spot welds to be "More than 1.3x the number of welds made by the manufacturer."
• states to "Avoid welding over previously welded areas."

Toyota/Lexus Spot Welding Requirement/Recommendation

Per the Making Holes For Plug Welding: "For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding."

Plug Welding

Toyota/Lexus does not indicate a specific plug weld nugget size in their collision repair information.

The Making Holes For Plug Welding area:

• states "For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding."
• provides a chart that identifies the diameter size of the plug weld hole based on the panel thickness to be welded.

It is often asked, "If the procedure identifies the use of plug welds, can spot weld be used instead?" Toyota/Lexus also provides the additional clarification in their Collision Repair Information Bulletin (CRIB) #181 - Welding Specifications & Substitutions: "STRSW may be substituted for GMAW/MIG plug welds, however, STRSW substitutions should match factory weld size, strength and appearance."

Where the spot weld and plug weld nugget size was not identified, refer to the Steel Spot And Plug Weld Nugget Size: UPDATE article. This article provides general guidelines.

Always refer to Toyota/Lexus service information for the most up-to-date CRIB information. Follow OEM welding requirements, including what nugget size is required, to help ensure a complete, safe, and quality repair.

For additional Toyota/Lexus information, check out the following pages:
Toyota OEM Information
Lexus OEM Information

Additional I-CAR Collision Repair News you may find helpful:
Back-To-Basics: Destructive Weld Testing
Collision Information Website Access: Toyota/Lexus/Scion
Dressing GMA Welds
How to Find Toyota/Lexus CRIBs
Steel Spot And Plug Weld Nugget Size: UPDATE
Step-By-Step: Accessing Toyota, Lexus, And Scion Repair Information
Weld-Through Primer Guidelines: Toyota/Lexus/Scion
Welding And MIG Brazing Hotspot

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