Spot-Weld Bonding Steel Components (Cooper, Cooper S, John Cooper Works)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2021 MINI Cooper, 2020 MINI Cooper, 2019 MINI Cooper, 2018 MINI Cooper, and 2017 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: Comply with the following topics :

Safety regulations (See INFORMATION ON HAZARDS (COOPER, COOPER S, JOHN COOPER WORKS) And SAFETY AT WORK (COOPER, COOPER S, JOHN COOPER WORKS) ).

Handling electrical system, electronics, airbags and restraint systems (See HANDLING AIRBAGS AND RESTRAINT SYSTEMS (COOPER, COOPER S, JOHN COOPER WORKS) And HANDLING ELECTRICAL SYSTEM AND ELECTRONICS (COOPER, COOPER S, JOHN COOPER WORKS) ).

WELDING STEEL COMPONENTS .

Beginning with E65 the spot-weld bonding process is used to increase vehicle rigidity. In partial body areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180°C).
In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled as a substitute for the omitted adhesive.
Minimum distance between welding spots (1) is 25 mm. Important: The minimum distance must not be undershot! If there is not enough space for twice the number of resistance weld points, each nonmade resistance weld point must be replaced by a MAG weld seam (2). Length of a MAG weld seam = 20 mm. Set the MAG weld seams at equal intervals distributed on the face.

Courtesy of BMW OF NORTH AMERICA, INC.
The following procedures are used as a substitute for spot-weld bonding:
- MAG welding (MAG welding)
- Resistance pressure spot welding (referred to in the following and in the repair instructions as spot welding).
Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints. Areas which cannot be reached by the spot-welding tongs can be joined by MAG plug welding. The number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to existing welding spots on new part. This is necessary because the adhesive between the spot flanges of the new part acts as an insulator
CAUTION: Extract smoke and fumes during welding work.