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 welding specifications in each vehicle-specific body repair manual (BRM). After you have logged into the subscription website and entered the vehicle information:

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

This document contains numerous categories. The Welding Work area identifies methods of welding two or more steel panels together, including ultra-high-strength steel (UHSS). The plug diameter, welding wire, and shielding gas are also specified here.

Spot Welding

Toyota/Lexus does not indicate a specific spot 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." for "Normal steel or high strength steel"
• Specifies the number of spot welds to be "More than the number of welds made by the manufacturer” for “980 MPa ultra high strength steel"
• States to "Avoid welding over previously welded areas."

Toyota/Lexus Spot Welding Requirement/Recommendation

Per 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 provides 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 Steel GMA Welds: UPDATE
• 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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Article validated in 2025