Mazda 6. Manual — part 401
I–8
EFFICIENT REPLACEMENT OF BODY PANELS
Rough Cutting of Damaged Panel
• Verify that there are no parts (such as pipes,
hoses, and wiring harness) nearby or on the
opposite side of a panel which could be damaged
by heat.
• For cut-and-join areas, allow for an overlap of
30—50 mm {1.18—1.97 in} and then rough-cut
the damaged panel.
End Of Sie
INSTALLATION PREPARATIONS
A6E203800026B02
Rough Cutting of New Parts
• For cut-and-join areas, allow for an overlap of
30—50 mm {1.18—1.97 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
2
gas shielded-arc
welder to make the plug welds.
MZZ2038B001
MZZ2038B002
MZZ2038B003
EFFICIENT REPLACEMENT OF BODY PANELS
I–9
I
Making Holes for CO
2
Arc Welding
• For places that cannot be spot welded, make a hole for CO
2
arc welding using a punch or drill as follows.
(mm {in})
• 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.
Application of Weld-through Primer
• For treatment against corrosion, remove the paint
grease, and other material from the portion of
new part and body to be welded, and apply
weld-through primer.
End Of Sie
EFFICIENT INSTALLATION OF BODY PANELS
A6E203800026B03
Checking Preweld Measurements And Watching
• Align to the standard reference dimensions,
based upon the body dimensions illustration, so
that new parts are installed in the correct position.
Board thickness (ø)
Hole diameter (ø)
0.60—0.90 {0.02—0.03}
5 {0.19}
0.91—1.20 {0.04—0.05}
6 {0.23}
1.21—1.80 {0.051—0.07}
8 {0.31}
1.81—4.50 {0.071—0.17}
10 {0.39}
MZZ2038B004
MZJ2038B008
MZJ2038B009
I–10
EFFICIENT REPLACEMENT OF BODY PANELS
Welding Notes
• For the number of weld points, welding should be
performed in accordance with the following
reference standards.
Spot Welding Notes
• The shape of the spot welder tip is D=(2×t)+3. If
the upper panel thickness is different from that of
the under panel, adjust to the thinner one.
• Because the weld strength is affected by the
shape of the spot welder tip, the optimum
condition of the tip should always be maintained.
• Spot welds should be made at points other than
the originally welded points.
• Before spot welding, make a trial weld using the
same material as the body panel to check the
weld strength.
MZZ2038B005
MZZ2038B009
MZJ2038B012
MZZ2038B006
EFFICIENT REPLACEMENT OF BODY PANELS
I–11
I
Checking Weld Strength
• Installation locations of the engine, chassis, and
seat belts are designated as important safety
locations for weld strength. Check weld strength
by driving a chisel between the panels at every
fourth or fifth weld spot, and every tenth regular
weld location.
• Drive the chisel between the panels according to
the number of panels as shown below.
• To determine weld strength, drive the chisel
between the panel and check whether the panels
come apart. If the panels come apart, make
another weld near the original weld.
• Restore the shape of the checked area.
End Of Sie
MZZ2038B007
MZZ2038B008
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