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Steel Spot And Plug Weld Nugget Size: Toyota/Lexus - UPDATE
I-CAR · April 22, 2020 · Toyota, Lexus
Summary
This article outlines Toyota and Lexus specifications for spot and plug welding, noting that while they do not specify a exact nugget size, they do mandate specific weld counts and plug hole diameters based on steel type and panel thickness. It also highlights that squeeze-type resistance spot welding (STRSW) can be substituted for plug welds if they match factory size, strength, and appearance.
What to do on the job
When spot welding, increase the weld count to more than 1.3 times the factory count for normal/high-strength steel, match the factory count for 980 MPa ultra-high-strength steel, and size plug weld holes according to the OEM panel thickness chart.
How to use it
Use this document to justify the additional time required for drilling specific plug weld hole diameters and performing extra spot welds (1.3x the factory count) as mandated by Toyota/Lexus repair guidelines. It can also be used to defend the substitution of STRSW for plug welds when appropriate.
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