Spot And Plug Weld Nugget Size: Volkswagen

Spot And Plug Weld Nugget Size: Volkswagen

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 Volkswagen has to say.

The Volkswagen Body Repair, Body Collision Repair manual specifies: "The basic principle for repair welding is to re-create as much of the original welded connection as possible." It also requires that: "the resistance spot welder is strong enough to produce weld spot diameters like at the factory." GMA (MIG) plug welding is used where spot welding arms cannot reach. General information about welding can be found in the Resistance Spot Welding category of the Body Repair, Body Collision Repair manual.

Volkswagen does not give a specific spot weld nugget diameter. The manual does, however, give a formula for calculating the correct spot weld nugget diameter based on the thickness of the panels being welded. Volkswagen states that test panels should be used before repairing the vehicle and to: "check all spot weld connections 100% with a chisel test."

Plug welding diameters can be found in vehicle-specific body repair manuals (BRMs). Repair procedures that use plug welding will specify what diameter drill bit to use for the plug welds.

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

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