How To (Plug Weld) For Auto Body Collision Repair Work – *Collision Repair Technology Program*

April 2, 2018 by Posted in: Auto Collision Repair

Collision Repair students recorded for Our collision repair technology program partnered with ABRN to provide ABRN HOW2 Tip. This is a …


20 comments on “How To (Plug Weld) For Auto Body Collision Repair Work – *Collision Repair Technology Program*

  1. Brian Wassman

    There are a few problems with this presentation.

    First the reason the two middle plug welds showed lack of heat was due to the coupon resting on the table. The metal from the thick table soaked up the heat from the weld.

    Second I-CAR doesn't recommend any size hole for welding, you should refer to the OE repair instructions on size of holes. There are general guild lines for hole size depending on thickness of panel. On thin gauge (below 20) 6mm hole and on think gauge (above 18) 8mm hole.

    Three I can tell you right off the bat that the welder settings are not quite right. The buzzing should be tight and consistent and from the looks of the visual the weld is too tall and wire speed should be backed down a touch.

    Fourth majority of HSS and UHSS are not MIG/MAG welded due to the heat destroying the strength properties of the steel. They are spot welded, MIG brazed, or rivet bonded.

    Lastly welding coupons are great for practicing welding technique. When testing welds that are to put on a specific vehicle it is best to use same thickness and alloy for testing. This material can be acquired from the panel that was removed.


  2. Donnie Smith

    @RaysRacing1 Horizontal is being referred to as a vertical upright position welding from one side to the other. (right to left) We refer to a vertical upright position weld as an upright position welding from top to bottom (up and down) sorry for the confusion.


  3. awesomeluis

    @ButlerCollision 5/16" makes sense. I used the 3/8" spotweld cutter from napa to remove the old spotwelds. I used a 1/8" drill bit to make pilot holes so the cutter wouldn't walk all over the place. So now I have 1/8" holes on the piece I wanna weld back on. Would you recomend I redrill them to 5/16" to plug weld them into place?? Thanks for such a helpful video by the way.


  4. Donnie Smith

    @awesomeluis 8Mmm or 5/16 inch is the i-Car recommended size. This is the most common from most car manufacture recommendations. However, there are times they may specify different sizes for specific weld locations. Thanks for watching!


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