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 Kia has to say.
Kia provides their welding requirements in one central location in the body repair manuals (BRMs) under: Body Repair ➤ Body Repair Manual ➤ Body Panel Repair Procedure - General Information This page is broken down into numerous categories that highlight spot welding and GMA plug welding.
For example, information about the welding requirements for a 2026 Kia EV9 can be found under: Body Repair > Body Repair Manual ➤ General Information ➤ General Information. This document has a different layout and wording, however it contains similar information.
Spot Welding
Kia does not indicate a specific spot weld nugget size in their collision repair information.
Kia body repair manual states in the Determining a Welding Method category: "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."
Kia also provides a chart that determines what diameter plug weld hole is needed, depending on panel thickness.
Some key spot welding instructions from Kia:
- It is the most reliable welding method.
- If the thickness of the panel is greater than 3 mm, check the weldability during the double-sided spot welding. If there is a problem, perform GMA plug welding.
- Increase the number of spot welds by 30% (1.3 times the original number of welds).
Kia Spot Welding Requirement/Recommendation
Per the Kia Determining a Welding Method chart, spot welding is: "the most reliable welding method (provides high efficiency and quality of assembled part)."
Plug Welding
Kia does not indicate a specific plug weld nugget size in their collision repair information.
It is important to note that the Kia body repair manual states in the Determining a Welding Method category: "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."
Kia also provides a chart that determines what diameter plug weld hole is needed, depending on panel thickness.
Kia states the following about the use of GMA plug welds:
- "Use when spot welding can’t be done or spot welding is not necessary."
- "Do not exceed 1 mm of space between parts. A tolerance greater than 1 mm will reduce the strength of the welded area."
- "Same number of welds as the number of factory welds."
It is important to note that whether using spot welds or GMA 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."
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 Kia information, check out the Kia OEM Information page.
Additional I-CAR Collision Repair News you may find helpful:
- Back-To-Basics: Destructive Weld Testing
- Collision Information Website Access: Kia
- Dressing Steel GMA Welds: UPDATE
- Steel Spot And Plug Weld Nugget Size: UPDATE
- Step-By-Step: Accessing Kia Repair Information
- Weld-Through Primer Guidelines: Kia
- Welding And MIG Brazing Hotspot
Related I-CAR Courses
Article validated in 2025