Steel Spot And Plug Weld Nugget Size: Mazda - 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 Mazda has to say.

Information on spot welds and plug welds can typically found in two areas of vehicle-specific body repair manuals.

Spot Welding

Mazda does not indicate a specific spot weld nugget size in their collision repair information.

Spot weld information is located under: Bodyshop ManualsGeneral InformationEfficient Installation of Body Panels. Here you will find information on the number of replacement spot welds required, as well as additional notes. For example:

  • "Spot welds should be made at points other than the originally welded points."
  • "Before spot welding, make a trial weld using the same material as the body panel to check the weld strength."

Mazda Spot Welding Requirement/Recommendation

Per our contact at Mazda: “For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows."

Plug Welding

Mazda does not indicate a specific plug weld nugget size in their collision repair information.

Plug weld information is located under: Bodyshop ManualsGeneral InformationInstallation Preparations. In this location you will find a chart that provides panel thickness and the corresponding hole diameter that will need to be made. There are several important notes to be aware of:

  • "For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows." (See chart provided in the body repair manual.)
  • "If the total thickness at the area to be welded is 3 mm (0.12 in) or more, use a gas shielded‐arc welder to make the plug welds."

Per our contact at Mazda: "If the repair procedure shows plug welding spot welding can be used instead, following the information listed in the General Information section of the BRM."

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.

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

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

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


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