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

Subaru gives a chart of spot and plug welding guidelines in the Foreword of each vehicle-specific body repair manual (BRM). To find this information:

1. Log on to the Subaru service site
2. Go to the Quick Reference Search area of the webpage
3. Select Service Manual from the Choose Publication Type dropdown
4. Search for a vehicle by entering a VIN and click Search
5. Open the BRM by clicking on the download icon to the right

The chart specifies what spot welding current, compression, and welding time is required for different panel thicknesses. On the same chart, specifications for plug welding are also given.

Spot Welding

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

Per the body repair manual, Foreword:

• "For new spot welding, avoid previously welded locations.
• After spot welding, inspect the welding locations, and if the weld appears to be insufficient, perform plug welding."

Subaru Spot Welding Requirement/Recommendation

"At locations where spot welding is not possible, use a punch or a drill to open holes for plug welding..."

Plug Welding

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

The BRM Foreword provides an additional plug weld hold diameter to panel thickness chart.

The BRM also calls out spot welder settings required for the ultra-high-strength steel (UHSS) body components being welded within replacement procedures.

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 Subaru information, check out the Subaru OEM Information page.

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

• Back-To-Basics: Destructive Weld Testing
• Collision Information Website Access: Subaru
• Dressing Steel GMA Welds: UPDATE
• OEM Linking Pin: Subaru Spot Weld Settings
• OEM Linking Pin: Subaru Welding Wire And Gas Clarification
• Reading Subaru Repair Procedures: UPDATE
• Steel Spot And Plug Weld Nugget Size: UPDATE
• Step-By-Step: Accessing Subaru Repair Information
• Weld-Through Primer Guidelines: Subaru
• Welding And MIG Brazing Hotspot

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