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Kia Sportage: Spot welding

Kia Sportage - Second generation (JEKM) (2005-2015) - Body Workshop Manual / Replacing body panels / Notes when welding body / Spot welding

1. Commercial spot welding machines do not perform as well as the machines used in the manufacturing process. When spot welding, increase the number of spot welds by 30% (1.3 times the original number of welds).

2. When spot welding, weld in the middle of the joint.

Spot welding on the edge of the joint will reduce welding strength.

Carbon arc welding

Carbon arc welding

In areas where spot welding is not suitable, do plug welding using a carbon arc welding machine.

1. Clamp the parts to be welded together tightly. Do not exceed 1 mm of space between parts. A tolerance greater than 1 mm will reduce the strength of the welded area.

2. Weld in the middle of the flange joint.

Drill a hole 5~6 mm on one side of the flange only, and weld within the hole.

Do not weld on the edge of the flange joint.

Disassembly - Replacing body panel

Disassembly 1. Body measurement Before disassembling, measure the damaged area according to the dimensions supplied in Body Dimension, Section 31. If deformation is present, use a frame straightener to adjust. When disassembling a panel,

Preparation for assembly - Replacing body panel

Preparation for assembly 1. Spot weld finish Use a disk grinder or similar tool to finish spot weld mark. Do not grind more than is necessary to smooth surface. 2. Panel preparation Repair any bent or uneven areas with a hammer to improve th

Assembly - Replacing body panel

Assembly 1. Checking welding and fitting in advance When assembling a new part, measure the dimensions of each part according to the body dimensions given in Section 31, and set part to the reference dimensions. Prior to final weld

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