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Steel Spot And Plug Weld Nugget Size: Ford/Lincoln - UPDATE
I-CAR · November 13, 2019 · Ford, Lincoln
Summary
This article outlines Ford and Lincoln requirements for steel spot and plug welding, highlighting that factory welds can be substituted with either Squeeze-Type Resistance Spot Welding (STRW) or MIG plug welds. It emphasizes that technicians must reference the vehicle-specific Weld Nugget Chart in the 501-25 Body Repairs manual to determine the correct weld nugget diameter based on metal thickness and layering.
What to do on the job
Reference the vehicle-specific Weld Nugget Chart in the 501-25 Body Repairs manual to determine the correct nugget diameter, and ensure all plug weld holes are drilled to exactly 8 mm (0.31 in) in diameter.
How to use it
Use this document to justify the time and precision required to measure metal thickness and reference the Weld Nugget Chart. It also supports the necessity of drilling 8 mm plug weld holes and performing destructive weld testing to match OEM specifications when substituting factory welds with STRW or MIG plug welds.
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