Current Level High for Both Welds
Current Level Adjusted to Provide Acceptable Welds
1. Select the proper spot welding tong/arm which
provides the best access to the areas of the vehicles where the spot welds are to be made.
2. Obtain metal of the same thickness and coating (i.e., bare, galvanneal, or galvanized) to be welded. This metal
will be used for spot welder set up. Damaged sheet metal taken from the vehicle being repaired may be used if
it is from the area from which the work is to take place. The sheet metal must be flat, free of cracks, wrinkles
and scored metal.
3. Using the procedure outlined in
Test Weld Coupon, prepare the test coupons.
4. Clean and prepare both mating coupons. If using adhesives, verify the recommendations of the adhesive
manufacturer. All contaminates such as rust scale, dirt, paint, and existing sealers and adhesives must be
removed. Remove any E-coat within 25 mm. (1 in.) of where the welds are to be placed.
5. If the panel joint originally contained structural adhesive, it should be applied to the coupon at this time.
6. Install the equipment manufacturers recommended electrode tips.
7. Adjust the welding electrode tip force, and clamp time per manufacturer recommendations.
NOTE: Galvanneal and galvanized coated steel will require more force
8. As shown in Test Weld Coupon, place first weld at a position at least 12.5 mm. (0.5 in.) away from end weld
coupons. Then make the second weld. The weld spacing should be the same distance as the original welds or
the closest existing weld, whichever is the least on the vehicle being repaired.
9. Destructively test the second weld to determine the size of the resistance spot weld produced (see examples
1 - STRUCTURAL ADHESIVE
2 - WELD HAS HEAVY EXPULSION OF METAL AND SUR-
FACE MARKINGS
3 - WELD CORRECT SIZE
1 - STRUCTURAL ADHESIVE
2 - WELD CORRECT SIZE
3 - WELD CORRECT SIZE
RU 31 - Collision Information 31 - 37
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