Installation Preparations; Rough Cutting Of New Parts; Determination Of Welding Method; Making Holes For Co 2 Arc Welding - Mazda 6 2009 Bodyshop Manual

INSTALLATION PREPARATIONS

Rough Cutting of New Parts

• For cut-and-join areas, allow for an overlap of 30—50 mm {1.2—1.9 in} with the remaining area on the body
side and then rough-cut the new parts.

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO
make the plug welds.
Making Holes for CO Arc Welding
2
• For places that cannot be spot welded, make a hole for CO
Panel thickness (φ)
0.60—0.90 {0.024—0.035}
0.91—1.20 {0.036—0.047}
1.21—1.80 {0.0477—
0.0708}
1.81—4.50 {0.072—0.177}
• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates
are put together. Also, weld the plates together tightly so that gaps do not develop.
00-00–16
GENERAL INFORMATION
(mm {in})
Hole diameter (φ)
5.0 {0.20}
6.0 {0.24}
8.0 {0.31}
10.0 {0.394}
30 50 mm{1.2 1.9 in}
— —
OVER LAP
BODY SIDE ROUGH CUT LOCATION
NEW PART ROUGH CUT LOCATION
gas shielded-arc welder to
2
arc welding using a punch or drill as follows.
2
φ
10.0 mm {0.394 in}
30° 30°
id000000600400
30 50 mm{1.2 1.9 in}
— —
OVER LAP
am3uub0000008
3 mm
{0.1 in} OR MORE
am3uub0000008
OUTER PANEL
MIDDLE PANEL
INNER PANEL
am3uub0000008