Nissan Armada 2025-2026 Service and Repair Manual: Cutting Off Welded Portions

A vehicle body is constructed by using three different welding methods [spot welding, MAG and brazing]. Cutting welded portion by these methods is described below.

Spot welding is generally used on two or more overlapped panels. The tool or cut off method must be changed according to whether the panel to be removed is on the top, in the middle or on the bottom.

(1) CONFIRMING THE SPOT WELDED POSITION

Remove paint, undercoat, and sealer from the panel to confirm the spot welded positions.

(a) Using air sander, rotary wire brush, or file sanding belt:

When using this method, do not grind too much of the panel. Sand or brush the panel while confirming the spot welded portion.

(b) Using a chisel:

If the spot welded portion is indiscernible even after removing paint, insert the chisel blade between the panels and tap lightly with a hammer for confirmation.

(2) CUTTING OFF SPOT WELDED PORTION

(a) Using a spot cutter:

There are two types of spot cutters (a drill type and a hole saw type). When using the spot cutter, be careful not to cut the lower panel.

If it is difficult to weld from behind the lower panel, the spot cutter may be used to cut the spot welded portions without drilling the bottom panel.

The hole saw type spot cutter requires grinding of the spot weld after cutting. This requires additional work time.

(b) Using drill:

The drill may be used to cut welds from any portion welded by plug welding, by drilling out the plug welded portion.

(3) CUTTING SPOT WELDED PORTIONS WITH AN AIR SANDER

If the spot cutter cannot be used, use the air sander (or belt sander) to cut off the spot welded portion. Use 3M File Belt Sander #33573 and Cubitron II File Belt Grade 60+ #33445 or equivalent.

(4) REMOVING PANEL WITH A CHISEL

After cutting the spot welded portions, separate the panel using the chisel.

By doing this, spot welded portions will separate from their mating surfaces. Thus, work can proceed while confirming the separation of spot-welded portions.

(5) CUTTING MAG WELDED PORTIONS

The MAG welding method is divided into two types (plug welding and seam welding). The plug weld portion can be cut off with a spot cutter or the like. To cut off the seam welded portion, grind the seam-weld bead with an air grinder to cut the welded portion. Be careful to grind from the replacement panel. Do not grind the reused panel excessively.

(6) CUTTING OFF BRAZED PORTION OF PANEL

Brazing is used to improve the external appearance of the joined portion (roof and fender) of the body outer panel as well as to improve sealing. Brazed portions can be generally disconnected by dissolving the braze with an oxy-acetylene torch.

If arc brazing was used, cut off the welded portion with an air sander or the like. The melting temperature of arc brazed metal is higher than that of ordinary brazing, and the panel may be damaged by this high temperature. Ordinary brazing and arc brazing may be discriminated by observing the color of the brazed metal. Ordinary brazing looks like a brass, while arc brazing has a copper color.

(a) Cutting with pneumatic saw and file belt sanding.

Remove the metal with a wire brush and separate the panel. While the filler metal is still hot, insert the tip of a screwdriver or the like between panels to prevent re-adhesion.

(b) Cutting with an air grinder use 3M 01991 weld grinding wheel (or equivalent)

Cut off the brazed portion with the air grinder. Do not grind excessively the panel to be reused.

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