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Basic procedure for SG plug welds
♦ Remove spot welds with a spot weld cutter or grind them down.
♦ Detach damaged part (use a chisel if necessary).
♦ Grind down projecting material.
♦ Match up new part.
♦ Drill hole for plug weld in upper panel (for diameter, refer to
Workshop Manual for relevant vehicle).
♦ Clean flanges and remove oxide layer.
♦ Make plug weld, working outwards from centre.
Note
Riveting is also permissible in some cases. Refer to “Body Re‐
pairs” workshop manual.
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
WARNING
♦ Always use an extraction system when performing weld‐
ing and grinding work.
♦ Welding and grinding must never be performed simulta‐
neously in the same working area.
♦ Working area must be cleaned at regular intervals as nec‐
essary to remove dust.
♦ Compressed air must NOT be used to blow out dust de‐
posits.
♦ The extraction system must be cleaned at regular inter‐
vals.
♦ In addition, the relevant accident prevention and industrial
safety regulations must be observed.
6.3 SG continuous seams and stitch weld
seams
SG continuous seams and stitch weld seams are primarily used
for joining parallel or overlapping surfaces. Due to the very high
welding temperatures and the associated change in the proper‐
ties of modern materials, the areas in which this joining technique
are used are becoming increasingly restricted. It is essential to
refer to the Workshop Manual for the relevant vehicle in such ca‐
ses.
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
General InformationBody Repairs, General Body Repairs - Edition 04.2018
6. Thermal joining techniques 25
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