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