Close
MENU

Follow us on @Ask_ICAR for daily updates.

Home / Collision Repair News / Steel Spot And Plug Weld Nugget Size: Ford/Lincoln - UPDATE

Steel Spot And Plug Weld Nugget Size: Ford/Lincoln - UPDATE

Posted on 13 November 2019 | Share:
| Print Print

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 Ford/Lincoln has to say.

Spot Welding

Ford/Lincoln provides a Weld Nugget Chart within vehicle-specific body repair manuals in the 501-25 Body Repairs – General Information, Specifications document. This chart provides the configurations of different metal thickness to be joined and the corresponding plug 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 specifies which types of steel can be spot or plug welded.

Per the Ford/Lincoln Workshop manuals, Welding Precautions document:

  • "Factory welds may be substituted with either STRW or MIG plug welds."
  • "Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld location."

Ford/Lincoln Spot Welding Requirement/Recommendation

Ford does not indicate a spot welding vs. plug welding preference in their collision repair information.

Plug Welding

Ford/Lincoln provides a Weld Nugget Chart within vehicle-specific body repair manuals in the 501-25 Body Repairs – General Information, Specifications document. This chart provides the configurations of different metal thickness to be joined and the corresponding plug 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.

Per the Ford/Lincoln Workshop manuals, Welding Precautions document:

  • "Factory spot welds may be substituted with either STRW or MIG plug welds."
  • "Plug weld hole should equal 8 mm (0.31 in) diameter."
  • "MAG plug welds must equal factory welds in both location and quantity."

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.

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

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

Additional I-CAR Collision Repair News you may find helpful:

Related I-CAR Courses

Course Ford Collision Repair Overview

Course Introduction to Squeeze-Type Resistance Spot Welding

Course Squeeze-Type Resistance Spot Welding Hands-On Skills Development

Course Steel GMA Welding Theory

Course Training and Certification: Steel GMA Welding

Course Welding Training and Certification

  • Repairer Driven News: Rivian Updates Door Handle Procedure Sunday, 4 February 2035

    Repairer Driven News (RDN) released an article featuring an updated Rivian procedure.

  • 2025 SkillsUSA National Competition Results Monday, 30 June 2025

    The 2025 SkillsUSA National Leadership and Skills Conference took place on June 26, 2025. Every year I-CAR sends volunteers (virtually in 2021) to judge the collision repair technology competition....

  • Ford/Lincoln Rocker Panel Reinforcement Sectioning Friday, 27 June 2025

    We are often asked, “Can I section this panel?” Let’s take a look at Ford/Lincoln vehicles and sectioning the rocker panel reinforcement.

  • Back-To-Basics: Backside Panel Refinish And Edging Thursday, 26 June 2025

    Sometimes, going back to the basics can make the difference between a quality repair and a failed repair. When repairing and refinishing, you might need to refinish the panel's backside and edges.

  • Hyundai Position Statement: Pre- And Post-Repair System Scanning - UPDATE Monday, 23 June 2025

    Hyundai released an updated position statement relating to pre- and post-repair system scanning.

  • App-Based Connected Services Considerations Tuesday, 17 June 2025

    Have you had an experience where the vehicle notified the owner that it was being moved while it was in your repair facility? App-based connected services are available from many vehicle makers and...

  • Digital Key Considerations Tuesday, 17 June 2025

    The intermingling of technology and automobiles continues, with digital key offerings from most vehicle makers. Digital keys utilize smartphone technology to expand vehicle access and owner...

  • Back-To-Basics: Tire Tread Pattern Wednesday, 11 June 2025

    Sometimes going back-to-basics can make the difference between a quality repair and a failed repair. Let’s see how to identify tire tread patterns and their repair considerations.

  • Corrosion Protection Guidelines: Ford/Lincoln - UPDATE Tuesday, 10 June 2025

    A key factor in collision repair is making long-lasting repairs. When a vehicle is repaired, many areas of corrosion protection are disturbed. This creates corrosion hot spots that, left untreated,...

  • Rivian Restraints Wiring Thursday, 5 June 2025

    The question is often asked, "Can supplemental restraints system wiring be repaired?" The answer is: it depends on the vehicle maker. Let's take a look at Rivian's position on this subject.

Top Ten Vehicle Specific Questions

Hyundai Does Hyundai have a sectioning procedure available?
2014 Jeep CherokeeIs there a procedure available for resetting the active headrestt?
Kia Does Kia have a sectioning procedure available?
Chevrolet Does Chevrolet have a warning against sectioning when there is no procedure?
BMW Can I-CAR send me BMW repair procedures?
Hyundai Does Hyundai have part replacement procedures available?
Honda What does Honda say about repairing damaged airbag system wiring harnesses?
Mercedes-Benz Can I-CAR send me Mercedes-Benz repair procedures?
Honda What does Honda say about straightening front lower rails?
Subaru Do you have to replace a front passenger airbag on a Subaru even if the airbag did not deploy? The repair information seems to indicate that it should.

Top Ten I-CAR Specific Questions

What does I-CAR say about using a recycled quarter panel assembly that includes the inner, outer, and reinforcements?
What does I-CAR say about straightening a kink?
What does I-CAR say about the decision to use recycled parts?
What does I-CAR say about replacing suspension parts in pairs?
Can I-CAR General Sectioning Guidelines be used?
What does I-CAR say about repair tolerances?
What does I-CAR say about repairing damaged door intrusion beams?
What does I-CAR say about repairing damaged bumper reinforcements?
What does I-CAR say about using recycled airbags?
What does I-CAR say about repairing damaged crush boxes?