Fiat 500 Collision Awareness Manual page 49

2012 FF
1. Select the proper spot welding "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, (Fig. 19), prepare the
test coupons.
4. Clean and prepare both mating coupons. If using ad­
hesives, 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 E­coat within 25mm. (1in.)
of where the welds are to be placed.
5. If the panel joint originally contained structural adhe­
sive, 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 (Fig. 19), place first weld at a position at least 12.5mm. (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 in
(Fig. 20) If the weld is insufficient, adjust the welder per the welder manufacturer recommendations and repeat
steps 7,8 and 9 until the proper weld size is achieved.
NOTE: If the first weld becomes too "hot" before the second weld reaches the correct size, reduce the current
settings for the first weld and continue increasing the current setting for the second weld until the proper size
for the second has been reached.
COLLISION INFORMATION
Fig. 24 Current Level Medium for Both Welds
1 ­ STRUCTURAL ADHESIVE
2 ­ WELD CORRECT SIZE
3 ­ WELD TOO SMALL
Fig. 25 Current Level Medium (2) High (3)
1 ­ STRUCTURAL ADHESIVE
2 ­ WELD CORRECT SIZE
3 ­ WELD CORRECT SIZE
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